1998 Exhaust Heat Shield Occasionally Touching Rear Silencer. Shall I

[Konrad C]

Since I replaced my exhaust last year, I have not been happy with it.

The front pipe and catalytic convertor are fine. I replace the stainless steel nuts and bolts with zinc plated bolts, as they suffer from galling and the threads seize due to the heat. I replaced the gaskets.

I mistakenly changed the rear system Klarius system for another, back in November which initially seemed to help. I thought the first was faulty.

The system is a lot smoother now after lots of adjustments, but after driving a long time, espacial on the motorway, the back box gets hot and touches the heat shield.

Fastbob wrote the following in another post: -

They are pretty much a problem on any car that has a heat shield, I ended up. bining mine on my Avensis when I replaced the exhaust, haven't had any problems from doing so.

Bob was this the rear heat shield? My shield is intact.

My other option is to repair my original exhaust by cutting the 8" rusty piece and weld a new piece to the 95% stainless steel system.

Or, buy the Euroflo mid and rear system. Has anybody fitted the Euroflo exhaust?

The Klarius has a resonance at 2400 - 2600 rpm which is about 60 - 65 mph very irritating, especially when hot. I can drive around it when going slower in lower gears.

I think it something to do with design of the Klarius back box.

[Konrad C]

I just saw this post on the Carina forum regarding looking for an exhaust:

http://www.toyotaownersclub.com/forums/topic/168689-searching-for-carina-e-exhust-system/#entry1391081

I would ask a similar question but for the mid/rear part.

[TomdeGuerre]

Konrad re the resonance you're getting from the Klarius box, yes, it can be very annoying on a long run. I had an Escort with a similar problems once. Mate of mine was a heating and ventilation engineer, he got me two lightweight steel clamps (like big jubilee clips but bolted together) which I put round the silencer body but they didn't make any difference. Then he got me some lead flashing they used for vents that go through roofing. It's not very thick stuff so I put a single wrap of that around the silencer, replaced the clamps and it seemed to work - to a degree. You'd probably need to get an acoustics engineer to explain just why, all I can tell you is that it wasn't as noisy or annoying.

[Konrad C]

Konrad re the resonance you're getting from the Klarius box, yes, it can be very annoying on a long run. I had an Escort with a similar problems once. Mate of mine was a heating and ventilation engineer, he got me two lightweight steel clamps (like big jubilee clips but bolted together) which I put round the silencer body but they didn't make any difference. Then he got me some lead flashing they used for vents that go through roofing. It's not very thick stuff so I put a single wrap of that around the silencer, replaced the clamps and it seemed to work - to a degree. You'd probably need to get an acoustics engineer to explain just why, all I can tell you is that it wasn't as noisy or annoying.

Tom,

You may have hit the nail on the head! The Klarius back box has mainly flat sides, where as most exhausts are always oval. Also I have noticed extra padding stuck to the outside, or metal weights on the end of exhaust silencers. This is to reduce the resonance, hence the volume of noise. Also the shape of the Klarius means it closer to the under body shield. Add the fact it may be made of aluminium instead of stainless steel, could be another contributory factor.

The original exhaust which I still have.

The Klarius exhaust.

Notice the more oblong shape of the Klarius compared to the original exhaust.

Now the reason why I had to change the exhaust:

The mild steel metal has corroded close to the weld.

This is the only section of mild steel on the exhaust and the flange is not too healthy either. It is about 8 inches long and ends just inside the first silencer. This is why I am looking at welding a new piece.

If this had been made of stainless steel, the exhaust would still be on the car.

My other option is looking at Euroflo and is their exhaust more like the original? It cost £50 so is not expensive. It is made of the same materials as the Klarius.

The search continues.

Konrad

[Druid Boy]

Can't you bend the mounting points to create enough clearance between the back box and heat shield? Or find longer mounting rubbers from a different model to drop the box away from the body a bit?