Neither the weld or its heat affected zone is the problem. Neither is the workmanship IMO.

 

The nipple broke right off of the muffler/resonator. That is a defect in workmanship/materials and should be covered - hands down.

I would not weld that - I would demand a replacement if they give you any problems. If the warranty is only for 1 year - and it is just after 1 year - buyer beware on Injen SES exhausts.

The packing and rest of the internals of the unit all tie together behind that area - so there is likely other internal breakdown issues going on as well. A weld job is likely only going to mask the problem, and once you do that, you will not be able to get replacements. A break like that is usually caused by severe binding in the system as well as the defect or poor build quality.

Take it from a manufacturer who would warranty it without question otherwise.

Rick

 

I sent an email to Injen to discuss options with my cracking problem (see below).

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To whom it may concern,
I purchased and installed the Injen SES1992C Dual Exhaust System on 8/14/2005. Sometime last year I noticed an exhaust leak noise coming from the drivers side and found a crack in the drivers side front resonator cap (see attached DSC04223). I took the car to a muffler shop and had this crack welded which solved the problem short term.
I found another set of resonator sections for sale last year ($200) and decided to purchase them for future use. I contracted a weld shop to add a weld ($60) in the sharp transition zone of both front and rear resonator caps (see DSC05159 and DSC05160) in hopes this will reinforce this area and provide a radius that will spread out the stress.
Sure enough, this week I noticed another exhaust leak noise and found both rear resonator caps cracked on the 2005 resonator pipes (see DSC05164). The other resonator pipe is still attached to the car.
I was ready to install my modified 2006 resonators pipes and found the inlet and discharge flanges did not match the original 2005 flanges. The 2005 inlet flange has a reducing section from 2-1/4 tubing to 1-7/8 tubing, so the flange is much larger than the 2006 inlet flange. The 2005 discharge flange is smaller than the 2006 discharge flange. Needless to say, I will have to either repair the 2005 resonator pipes at a cost of $60 and throw away my modified 2006 resonator pipes ($260 loss) or cut the 2005 flanges off and weld them to the 2006 resonators at a cost ($???). Can you explain why you changed the flange sizes please? Can you make any suggestions on how to solve my dilemma?

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That system was redesigned to use the "H" pipe, and required different size flanges.

Product & Marketing Support
Injen Technology Co. Ltd.,
285 Pioneer Place
Pomona, CA. 91768

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I spent effort to describe my issues with your product. The main issue is the failure of the resonator caps (I now have 3 cap failures). The cap failure is the root cause of my current installation problem. I did not specifically ask a question about the cap failure below, but can comment on this problem?

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The cracks may be due to stress and heat. There are too many variables to narrow down the reason for the cracks. You can get flanges put on the modified section you have so that it will work on your application.

Product & Marketing Support
Injen Technology Co. Ltd.,
285 Pioneer Place
Pomona, CA. 91768

---------------------------------------------

Shooter

 

I am unhappy with the design of the endcaps on the resonators. They are stamped out of very thin material with no relief radius. This causes a high stress area that will crack under "heat and stress" (hmmm does the exhaust get hot?). I love the sound though and will continue to modify this exhaust to make it work.

 

I don't think I would continue doing business with these clowns.

 

wow, what are you guys doing up at this time??

this forum takes up so much of my precious time, lol. it's so addicting.

 

It's 8:35 here in Houston! I figure it's 6:35 in California. I get up at at 4:00 am every day to go to work. Some of us are early risers....

 

I hear ya cato, I wouldn't buy a new one from them but I will fix what i got.