Second Gen Muffler Pipe Cracked - Fisker Buzz Forums
Fisker Buzz Forums

User Tag List

Reply
 
LinkBack Thread Tools
Old 08-03-2018, 03:50 PM   #1 (permalink)
Deep Ocean in ATL
 
Join Date: Dec 2013
Location: Atlanta
Posts: 436
Mentioned: 7 Post(s)
Tagged: 0 Thread(s)
Quoted: 111 Post(s)
Default Second Gen Muffler Pipe Cracked

I heard an unsettling noise when I engaged SPORT mode turning on the ICE last week. It was the unmistakable rattle of exhaust vibration. I was able to put the Karma on a couple of ramps and crawled under to discover one of the pipes from the Center Pizza Box muffler was completely cracked all the way around just beyond the re-enforcing strap that was placed on the new level triangle muffler. It seems the design may have only moved the stress point to the point where the welded strap is located. Sorry, I didn't take a picture.

The good news after realizing I couldn't fix it myself, I took to a local muffler shop. They welded the pipe in 2 minutes and was good as new. Rattle is gone, muffler is working again. No charge! Beats paying $1200 for a new muffler.

The muffler was replaced under the Customer Appreciation Program a few years ago. It probably had less than 10K miles of ICE driving. Wonder if this is common to the new design.

Last edited by AlJOHN; 08-03-2018 at 03:58 PM.
AlJOHN is offline   Reply With Quote
Old 08-03-2018, 05:13 PM   #2 (permalink)
Senior Member
 
Join Date: Mar 2012
Location: South Florida
Posts: 3,011
Mentioned: 146 Post(s)
Tagged: 3 Thread(s)
Quoted: 494 Post(s)
Default

Quote:
Originally Posted by AlJOHN View Post
I heard an unsettling noise when I engaged SPORT mode turning on the ICE last week. It was the unmistakable rattle of exhaust vibration. I was able to put the Karma on a couple of ramps and crawled under to discover one of the pipes from the Center Pizza Box muffler was completely cracked all the way around just beyond the re-enforcing strap that was placed on the new level triangle muffler. It seems the design may have only moved the stress point to the point where the welded strap is located. Sorry, I didn't take a picture.

The good news after realizing I couldn't fix it myself, I took to a local muffler shop. They welded the pipe in 2 minutes and was good as new. Rattle is gone, muffler is working again. No charge! Beats paying $1200 for a new muffler.

The muffler was replaced under the Customer Appreciation Program a few years ago. It probably had less than 10K miles of ICE driving. Wonder if this is common to the new design.
It took a couple of design changes before they came out with a center muffler that didnít crack within a year.
Harleyguy is offline   Reply With Quote
Old 08-03-2018, 09:45 PM   #3 (permalink)
Senior Member
 
JCMorrill's Avatar
 
Join Date: Jan 2015
Location: Scottsdale, AZ
Posts: 829
Mentioned: 22 Post(s)
Tagged: 0 Thread(s)
Quoted: 254 Post(s)
Default

@Harleyguy!!! You're back ... as YOU!
JCMorrill is offline   Reply With Quote
 
Old 08-04-2018, 07:19 AM   #4 (permalink)
Senior Member
 
Join Date: Mar 2012
Location: South Florida
Posts: 3,011
Mentioned: 146 Post(s)
Tagged: 3 Thread(s)
Quoted: 494 Post(s)
Default

Quote:
Originally Posted by JCMorrill View Post
@Harleyguy!!! You're back ... as YOU!
Yes thank you
Harleyguy is offline   Reply With Quote
Old 08-06-2018, 12:05 AM   #5 (permalink)
Senior Member
 
buzinvest's Avatar
 
Join Date: Oct 2017
Location: (30 min. S. of Cleveland, Ohio)
Posts: 347
Mentioned: 7 Post(s)
Tagged: 0 Thread(s)
Quoted: 81 Post(s)
Garage
Default

Welcome back!
__________________
Buzinvest
Signature Car #13, Silver Mirage, Tri-Tone Mohave
buzinvest is offline   Reply With Quote
Old 08-06-2018, 09:48 AM   #6 (permalink)
Senior Member
 
Join Date: Oct 2011
Location: Corona del Mar
Posts: 298
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 60 Post(s)
Default

37k miles and i'm on my 3rd muffler
__________________
2012 Fisker Karma EC Earth/Earth #1466
Purchased 3/24/2012
ufojoe is offline   Reply With Quote
Old 08-09-2018, 08:28 PM   #7 (permalink)
Deep Ocean in ATL
 
Join Date: Dec 2013
Location: Atlanta
Posts: 436
Mentioned: 7 Post(s)
Tagged: 0 Thread(s)
Quoted: 111 Post(s)
Default

Welcome "back" Harley....

The welding seems to have worked for now. Also the "muffler guy" said come back if I have any issues, he can repair. Don't know what that means but at the price of the muffler, I'll give him a try. It appears the stress bands moved the cracking further down the pipe. Stress must be coming from something else --- seemingly flex between the ICE an body mounts on the side canisters (resonators?). A possible solution would be replace the rigid connection pipes with flexible piping to the outer canisters. I will be looking to find some short flex pipes to replace them.
AlJOHN is offline   Reply With Quote
Old 08-10-2018, 06:01 PM   #8 (permalink)
Early Adopter
 
Nin ja's Avatar
 
Join Date: Jan 2012
Location: Virginia
Posts: 1,231
Mentioned: 12 Post(s)
Tagged: 0 Thread(s)
Quoted: 216 Post(s)
Garage
Default

Quote:
Originally Posted by ufojoe View Post
37k miles and i'm on my 3rd muffler
I had mine done by FiskerPhilly shortly after getting my car and to date no issue -- it pays to pay for quality - thanks Joe for fine job!
__________________
Karma Ecosport eclipse / dune
Nin ja is offline   Reply With Quote
Reply

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Similar Threads
Thread Thread Starter Forum Replies Last Post
Pipe Dream? vapevine.ca Fisker Karma 8 09-22-2016 11:27 AM
Stillen VS Bosal Muffler Harleyguy Fisker Karma 44 02-01-2016 10:48 PM
Broken ICE/GEN coupler FiskerPhilly Fisker Karma 9 05-27-2015 08:56 PM
Muffler problems and possible solution ejo3rd Fisker Karma 10 09-16-2013 08:22 PM

Powered by vBadvanced CMPS v3.2.3

All times are GMT -4. The time now is 06:03 AM.



Powered by vBulletin® Copyright ©2000 - 2020, Jelsoft Enterprises Ltd.
Search Engine Friendly URLs by vBSEO 3.6.0 PL2
Garage Plus vBulletin Plugins by Drive Thru Online, Inc.
User Alert System provided by Advanced User Tagging (Pro) - vBulletin Mods & Addons Copyright © 2020 DragonByte Technologies Ltd.
vBulletin Security provided by vBSecurity v2.2.2 (Pro) - vBulletin Mods & Addons Copyright © 2020 DragonByte Technologies Ltd.