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Discussion Starter · #1 ·
I met with Lormax last week and he pointed out my muffler was broken at the flange where it hard mounts to the exhaust manifold. He suggested a new muffler since his experience with repairs was not good. Since a new muffler is rather expensive I stopped by a local custom exhaust shop. He welded mine and said it was cracked nearly all the way around. It really made a big difference in the sound. Mine must have been cracked since I bought the car.

The shop owner made a suggestion to prevent a recurrence. His idea is to install longer studs and springs to hold the flange in place rather than the hard mount Fisker did. This would provide a little give when the engine torqued rather than putting the stress on the weld.

Do any of the tech people on the board see any reason not to try this?

Lormax is trying to find the specs on the studs so I can give this a try. Once I know how it works I will post and let you all know.

If anyone has the stud specs handy please let me know so I can get them to the exhaust shop.
 

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I know they tried this on at least one or two cars at Fisker HQ. I don't recall if it ended up making any difference, to be honest. After multiple tries to get the Stillen mufflers to work, they finally just switched as many as possible on the engineering cars over to Bosal.
 

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Discussion Starter · #3 ·
Lormax, what is the failure rate on the Bosal? from reading other posts in the forum it sounds like those are breaking too.
 

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Haven't seen one Bosal break yet . Completely design change .I will post some pictures of both when I get a chance .
 

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I met with Lormax last week and he pointed out my muffler was broken at the flange where it hard mounts to the exhaust manifold. He suggested a new muffler since his experience with repairs was not good. Since a new muffler is rather expensive I stopped by a local custom exhaust shop. He welded mine and said it was cracked nearly all the way around. It really made a big difference in the sound. Mine must have been cracked since I bought the car.

The shop owner made a suggestion to prevent a recurrence. His idea is to install longer studs and springs to hold the flange in place rather than the hard mount Fisker did. This would provide a little give when the engine torqued rather than putting the stress on the weld.

Do any of the tech people on the board see any reason not to try this?

Lormax is trying to find the specs on the studs so I can give this a try. Once I know how it works I will post and let you all know.

If anyone has the stud specs handy please let me know so I can get them to the exhaust shop.
Does that new fix dramatically reduce engine noise heard in the cabin?
 

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@ejo3rd: What Harleyguy said, I haven't seen the newest style Bosal break yet (the one with the reinforcement over the arms). When the Bosal first came out, there was no reinforcement there and they were breaking at the arms sticking out that go into the cans. In fact I looked at a car yesterday for something unrelated, and found the original style Bosal with a broken arm that lead to the passenger side exhaust can.

Will update this post with pics soon.
 

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Not sure which I have but it is inevitable that I will have an exhaust issue? Have not and at 10500 miles
If you had a problem while the car was in warranty and the center muffler was replaced you have a Bosal . You can always look underneath the car and see if the center muffler is flat in the middle or has ribs on it . Look at my post showing the difference of the two mufflers .
 

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is there a way to order the new muffler. Mine is broken and I live in Arkansas. There is no dealer near me and my dealer won't work on it any more. I could pay to get if fixed but I need a way to order the muffler.
 
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