jvsantosmd

About 18 months agoI bought a high flow catted 3in O2 housing. About a year ago the thing broke between the welds just past the cat housing where the LOWER post-cat weld goes into the short tube before it reaches the flange. I went to ny muffler shop and had it welded, no problem for the next 6-8 months.
This morning cruising down the highway on my way home ( no bumps) I heard a noise, and then muffler-less engine sounds again. Got home, yes, the thing became undone at the old welds.
I have no clue what's going on except the vibration is undoing the welds. I have a small resonator just past the flange just to keep nise levels and ddrone in check.
Being the problem PAST the cat, I cannot say the cat isplugged up and therefore the back pressure is undoing the (heavy) duty) welds.
Any ideas?

flylow

what brand is the o2 housing?

also, if its plated and the muffler shop didnt clean it good before welding of course its going to break again. Welds dont stick to plating too good.. This may also mean you flex pipe is not going a good job when the engine torques and moves, putting stress on the exhaust system, making it snap at the same section everytime

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jvsantosmd

WAIT !!! After a thorough forensic investigation, this time it broke just BEFORE the cat intake. I can see the cat cells when I look down. They don't seem plugged or anything like that. Besides, the car was running just fine.
Besides a re-weld, my other option will be a catless O2 housing and live with the cel until I get a reflash. What do I do with the uncrewed unattached sensors if my new O2 housing comes without the bungs?
PS: no plating. good quality steel. NEW weld gave away.
downpipe is also 3in with a good movable flex joint.
O2 housings run about $180-$250 on some sites but they're $120
on eBay...any opinions here?

Joe_B

So it broke both times at the weld but at opposite ends? If so it's probably a bad weld job.
Is the O2 stainless, mild steel, cast? What about the flanges?

More times than most it's because of crappy welds if the piece isn't old. But over time mild steel will do that also when it's that close to that much heat (turbo, exhaust manifold, etc)

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jvsantosmd

Well, 2nd guy that asks which brand... Ultimate Racing (UR)
Both times the welds at the cat gave up and separated..
Is this a trend we in the forum should be aware of?
I am EXTREMELY OCD when it comes to putting aftermarket stuff in my car, no loose hangs or sloppy jobs allowed, I do check on progress on most of everything.
I checked how it was installed because I FEARED the turbo studs. I made sure ALL the exhaust pipes were adequately attached to their mounting brackets.