Belanger Hi Flow Cats Broken

[blackbeast99]

Under the car today for track prep, and noticed my driver side muffler moving pretty freely...checked a little deeper and found that my Belanger exhaust has cracked/broken off material almost all the way around the flange/collector area where it meets the headers. Has anyone else had this issue? Just FYI for others...to be on the lookout. I'll have it repaired and put back on the car.

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[Lawineer]

That's really strange. Hard to tell, but am I correct in that it looks like it cracked along the length of weld?

How long have you had them on there? That shouldn't happen.

[GTS Dean]

Looks like the installation may have had some components slightly out of line when the v-clamps were tightened up. Heat and repeated engine torquing have ended up relieving the stress. Be sure the flanges meet up nice and even all around after repair. You may need to check engine mounts and other exhaust system isolators as well.

[blackbeast99]

That's really strange. Hard to tell, but am I correct in that it looks like it cracked along the length of weld?

How long have you had them on there? That shouldn't happen.

Yes, basically right along the weld it seems, I'll have it pulled out to have a better look. I've had them about 1.5-2 years.

[blackbeast99]

Looks like the installation may have had some components slightly out of line when the v-clamps were tightened up. Heat and repeated engine torquing have ended up relieving the stress. Be sure the flanges meet up nice and even all around after repair. You may need to check engine mounts and other exhaust system isolators as well.

Maybe so, just chatted with Belanger to have it addressed. Thank you for the insight, seems reasonable.

[Lawineer]

Looks like the installation may have had some components slightly out of line when the v-clamps were tightened up. Heat and repeated engine torquing have ended up relieving the stress. Be sure the flanges meet up nice and even all around after repair. You may need to check engine mounts and other exhaust system isolators as well.

You'd think the exhaust wouldn't line up in the outlet if it was that bad. Exhausts generally aren't very fixed because they have so much thermal expansion. I can't remember, but is there much fixing it that the stress from thermal expansion would cause that to break? I can't imagine it would break like that anyway. It broke 360 degrees.

[Reaper]

It broke right along the flange where its thinnest. Either too many heat cycles weakened it or its in a bind somehow with the rest of the system. Maybe a new flange can be cut out of thicker steel and welded onto the existing flange and it can still fit inside this band clamp. I see this stuff all the time at our machine shop.

[blackbeast99]

It broke right along the flange where its thinnest. Either too many heat cycles weakened it or its in a bind somehow with the rest of the system. Maybe a new flange can be cut out of thicker steel and welded onto the existing flange and it can still fit inside this band clamp. I see this stuff all the time at our machine shop.

This seems to be the most likely case. I had a good conversation with Jon B about the rotation of the crank-shaft and why the driver's side would be prone to creating this (more rotational force from left to right with how the crankshaft spins). Belanger and Job B both have been super helpful this evening. It can/will be fixed and returned.

[TheWessss]

I track a lot, and was having a regular similar problem. So the new J-pipe to eliminate the down stream CAT doesn't come with the front OEM hanger and the mechanic who installed it didn't swap it over. For city driving I imagine it would have never been an issue. But Sebring has a way of shaking everything loose if you know what I mean. Since correcting the hanger problem haven't had an issue since. Headers and exhaust work its so important to get them hung right so they aren't putting stress in places it doesn't belong. May want to check that the front hanger is still there. Good luck

[blackbeast99]

I track a lot, and was having a regular similar problem. So the new J-pipe to eliminate the down stream CAT doesn't come with the front OEM hanger and the mechanic who installed it didn't swap it over. For city driving I imagine it would have never been an issue. But Sebring has a way of shaking everything loose if you know what I mean. Since correcting the hanger problem haven't had an issue since. Headers and exhaust work its so important to get them hung right so they aren't putting stress in places it doesn't belong. May want to check that the front hanger is still there. Good luck

Correct, no hanger comes with these, nor does a flex section where it meets the headers like the OEM unit...so at a minimum, I'm considering having one welded on and use it similar to the OEM unit.

[Jack B]

There were a few G2 cars that caught fire at track events due to cat failures.

[simon455]

Is there a flex coupler/flex pipe incorporated in that system?

[Steve M]

Is there a flex coupler/flex pipe incorporated in that system?

In what the OP showed?

No.

They eliminate the front exhaust hanger to give it the needed flexibility. Belanger has done the same thing for years with his headers (along with pretty much all other Viper header manufacturers out there).

They can make it with a flex pipe (including the front exhaust hanger), but it's an additional charge.

[jpmst3]

This is exactly why I opted for the flex pipe insert. Yes, it does cost more and creates a slight restriction, but the factory engineers put one in there for a reason.
I know most claim it is not necessary and there is still plenty of room for movement. When I see how much the length changes from expansion and the torsion transferred from the engine, I would rather err on the side of caution. I was even thinking the small flex section would mitigate some vibration which is a stressor as well.

Of course, It may just be some thinner material/bend or bad weld (?) for whatever reason.

I am just glad Belanger is taking care of it. JonB is a class act and also takes care of his customers any way he can.

[Old School]

The position of the flex section is critical. The farther it is from the engine, the less effective it is at isolating the engines motion. If it's mounted a couple of feet from the engine, it will just be moving up and down instead of flexing. It's an inherent problem with longer tube headers.

[Steve M]

Where it failed was not a weld.

That part of the pipe is expanded and flared to meet with the flange on the exhaust manifold that is held together with a v-band clamp. Forming that part of it is going to make the metal thinner in that spot.

A crack formed, and vibration took care of the rest.

[Gen5snake]

Where it failed was not a weld.

Correct.

[blackbeast99]

This is exactly why I opted for the flex pipe insert. Yes, it does cost more and creates a slight restriction, but the factory engineers put one in there for a reason.
I know most claim it is not necessary and there is still plenty of room for movement. When I see how much the length changes from expansion and the torsion transferred from the engine, I would rather err on the side of caution. I was even thinking the small flex section would mitigate some vibration which is a stressor as well.

Of course, It may just be some thinner material/bend or bad weld (?) for whatever reason.

I am just glad Belanger is taking care of it. JonB is a class act and also takes care of his customers any way he can.
This is the route we decided on as well - it shipped back out to me yesterday. Jon B and Belanger both explained in detail to me how/why, etc. Added the hanger, added the flex section as it's best for my application.

[jpmst3]

This is the route we decided on as well - it shipped back out to me yesterday. Jon B and Belanger both explained in detail to me how/why, etc. Added the hanger, added the flex section as it's best for my application.

Good deal, glad you got it sorted out with a quick fix. Piece of mind is also a valuable thing.

[blackbeast99]

Good deal, glad you got it sorted out with a quick fix. Piece of mind is also a valuable thing.
Indeed, Thank you!