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Ok, resolved all my issues and now a NEW, SAD one popped up. Whenever the ENGINE turns on the car makes a continuous VERY loud sound that comes out of both sides of the exhaust. This is accompanied with loud vibrations from the engine. Sounds like a muffler problem or maybe manifold problem (I don't know what a manifold is). Basically I can't drive the car in anything but Stealth mode. There is nobody here in Toronto that can help. Help?
 

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Deep Ocean in ATL
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Suggestion: If you can get the muffler from Fisker Philly, any good muffler shop should be able to put it on. It doesn't seem to be a difficult job or unique to the Fisker. I was going to upgrade mine in my Garage, but had other priorities come up.
 

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Deep Ocean in ATL
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David, the Only caution is to make sure the muffler shop refers to the manual for Jacking Points on the Fisker.
 

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I have just rebuilt a muffler. By cutting open the top section, I was able to see the poor quality welds inside. I have repaired all welds and added a bit extra. Takes some time to do this, BUT so much better than replacing it with a NEW muffler that has the exact same 95% failure rate as an original.
 

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The only way to fix the muffler problem is by adding a flexible pipe - it has been known in the industry for decades that without these, the pipes will break quickly, and considering the engine vibrates with an axis to the largest leverage vs. the exhaust installation, on the Fisker it will break almost instantly. The soution is so simple....... :mad:
 

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Great idea to be able to put in the flex pipe-- Not sure WHERE or HOW to find the space for one. If you have actually been into this area of the car, I think you will agree that some major modification would have to take place to add the flex pipe.
IF anyone has opened up one of these mufflers it is quite clear they were NOT welded properly. Look at the complete system before commenting. I have-- been there done that. I registered on the forums to help owners that are struggling with this problem and are seeking advice on what WILL CURE the broken muffler problem.
 

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The bosal exhaust doesnt break. Ive never had one break after removing the stillens (with the inferior welds) and replacing with bosal. Its solved the problem just fine. If anyone can chime in on having a bosal muffler fail I'd like to hear about it.
 

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Can you tell us how to tell from looking at these two mufflers, which one they have? May help to have that information. Will give a heads up to know what may happen at any time..
Thanks For the help!
 

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Can you tell us how to tell from looking at these two mufflers, which one they have? May help to have that information. Will give a heads up to know what may happen at any time..
Thanks For the help!

@FunCars4us - check out this post in an older thread, it has the picture you are looking for:

http://www.fiskerbuzz.com/forums/13-fisker-karma/4250-stillen-vs-bosal-muffler-2.html#post68937

The same thread contains lots of Stillen and Bosal muffler discussion.
 

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OK-- Now that I see the picture of the Stillen and Bosal, it is easy to see the difference. Also see how the body to pipe straps on the Bosal will help. The referenced failure points shown on the Stillen in that photo were NOT a problem on this unit. All the failed welds were internal. I cut the muffler open to expose the internal baffles and tubes. ALL of them were loose and/or cracked at the weld points. Additionally, two of the baffles are only welded to one side of the muffler and allowed to be "free-standing" inside the unit. After all internal welding was completed and "slots" made in the body for added welding to the formerly free-standing baffles, the unit was back together. I added straps similar to those used on the Bosal.
I got into this because I could not understand why it happens at all, let alone so frequently, Why a replacement should cost SO MUCH money, and why no one has tried to FIX one. Bottom line is: The Stillen is repairable.
 

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