Broken Downpipe... Thoughts on Next Steps?

[Otter11]

So this happened today... my downpipe split on my Stasis exhaust. I have a 06 B7 A4 2.0T Manual w Stage 2 REVO and a 034 HFC. What are my options for a new downpipe? With Stasis I believe I would have to order a new full exhaust and would like to avoid that if possible. I have looked around but haven't found a used one for sale. Thoughts?

Thanks in advance.

[QuattriumMT6]

Techtonic Tuning or Milltek both make aftermarket DP's for our cars.

[Otter11]

Techtonic Tuning or Milltek both make aftermarket DP's for our cars.

do you have any experience on how either of them will come together with an 034 HFC and a Statis exhaust?... do they line up and gaskets fit well? thank for the quick reply

[rkesh88]

Can't you take those pieces to an exhaust shop and ask them to make it whole again? Cut off broken flex and put new one on?

[QuattriumMT6]

do you have any experience on how either of them will come together with an 034 HFC and a Statis exhaust?... do they line up and gaskets fit well? thank for the quick reply

Not sure about personal experience with TT but I've only heard good things about hem plus they have an option for both OEM and aftermarket exhaust & and cat applications. I have Milltek and the quality seems decent as does fitment. I reused all the original bolts and gaskets. I'd personally have a muffler shop install just in case they need to make any minor adjustments you weren't expecting.

[yxri]

Clearly Just take off the exhaust and run open down pipe. If anything having the pipe break will now allows more air to flow. I say you take the rest of the StaTis exhaust off. No but honestly you can take it to an exhaust shop and they can re-weld a new flex pipe in for around 100.

[Okedokey]

Install a HFC and stop polluting everyone.

[yxri]

Install a HFC and stop polluting everyone.

He does have a HFC. Read OP's Post

[Otter11]

thanks for the feedback everyone! I am currently exploring the weld option from an exhaust shop.

[vce1232000]

thanks for the feedback everyone! I am currently exploring the weld option from an exhaust shop.

Imo the option to keep everything Stasis and economical.

[vce1232000]

Install a testpipe and stop being afraid to like a

ftfy..........

[Charles.waite]

Can't you take those pieces to an exhaust shop and ask them to make it whole again? Cut off broken flex and put new one on?

This.

[Sanjman]

It's just the flex pipe.... Common issue. Take it to a muffler shop and get a new flex pipe installed. At least yours broke off cleanly which means there's a defect there.

[Otter11]

Thanks again all. I was looking into calling Stasis to claim the warranty but out of business haha! uggh!

[Gmoney1147]

If it's the stock mid pipe I have one in my garage


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[Otter11]

If it's the stock mid pipe I have one in my garage

It is a Stasis downpipe 3 inch. thanks for the offer though. Anyone out there looking to part out a used Stasis exhaust?

[Charles.waite]

Just buy a 3" stainless flex pipe on eBay. Remove the downpipe and bring it to an exhaust shop (I wouldn't ask them to wed it on the car unless access is really easy). Done and done. I bet you would end up spending less than $100 out the door.

There's nothing magical about Stasis's flex pipes. And clearly, given how yours broke, there's nothing magical about their welding either.

[vce1232000]

Just buy a 3" stainless flex pipe on eBay. Remove the downpipe and bring it to an exhaust shop (I wouldn't ask them to wed it on the car unless access is really easy). Done and done. I bet you would end up spending less than $100 out the door.

There's nothing magical about Stasis's flex pipes. And clearly, given how yours broke, there's nothing magical about their welding either.

This is the best low cost method. In fact Im gloing on my 3rd flex pipe with my TT DP now.For some reason I keep blowing these out

[Theiceman]

Sorry to revive such an old thread but it is relevant to me today ..

I think I am going to my budies shop , have him put the car on the lift and help me out, I don't want to tie up his lift so want to be kind of economical with his time .. I have a few questions.

1. When I was there last night I looked up and saw three bolts. are these just regular bolts that go through holes on each flange ? If so its easy , just snap em off with an impact and put replacement's in snugged up so I can remove them again later . if they are nuts on studs then it becomes a bit of a nightmare as you can break off the studs.
2. I saw the rest of the pipe after the flex with what looked like a welded sleeve, then into the resonator . Did I not notice a connection some place or has this been monkeyed with . If so it may mean I have to cut off and resleeve.
3. Will I need a lift to get this piece even out of the car? or can I wangle it out on jack stands ?

any info would be helpful thanks

[yxri]

The down pipe and resonator are just clamped together. The bolts should be able to be impacted off

[yxri]

Sorry to revive such an old thread but it is relevant to me today ..


3. Will I need a lift to get this piece even out of the car? or can I wangle it out on jack stands ?

any info would be helpful thanks

I took off my resonators on jack stands. Not too difficult

[pezgoon]

Sorry to revive such an old thread but it is relevant to me today ..

I think I am going to my budies shop , have him put the car on the lift and help me out, I don't want to tie up his lift so want to be kind of economical with his time .. I have a few questions.

1. When I was there last night I looked up and saw three bolts. are these just regular bolts that go through holes on each flange ? If so its easy , just snap em off with an impact and put replacement's in snugged up so I can remove them again later . if they are nuts on studs then it becomes a bit of a nightmare as you can break off the studs.
2. I saw the rest of the pipe after the flex with what looked like a welded sleeve, then into the resonator . Did I not notice a connection some place or has this been monkeyed with . If so it may mean I have to cut off and resleeve.
3. Will I need a lift to get this piece even out of the car? or can I wangle it out on jack stands ?

any info would be helpful thanks

Are you talking about the 3 bolts holding the down pipe to the cat? Yes those are bolts and not studs

You should be able to get it out on stands, I almost got the DP with cat out that way and that adds a foot lol

I took off my resonators on jack stands. Not too difficult

There is a sleeve like yxri said, it'll be above the middle chassis support, it'll have two bolts that will probably be rusted and be complete bears to get off. I had to reuse mine so I heated them alittle with a propane torch sprayed some on blaster on them and they came off. They were still a pain the whole way off but I was able to reuse it all


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[Theiceman]

great info guys thanks ( yes I was taking about the cat flange ) . I may even have a sleeve clamp left over from my A6. I think this one may have been welded up at some point but this info is good. worse case I will cut her off. I love it when bolts snap off on exhaust , pop em out. at about 100 USD for a downpipe ( I think that's what it is called ) from aftermarket group does not justify messing around with welding a new sleeve.

[pezgoon]

great info guys thanks ( yes I was taking about the cat flange ) . I may even have a sleeve clamp left over from my A6. I think this one may have been welded up at some point but this info is good. worse case I will cut her off. I love it when bolts snap off on exhaust , pop em out. at about 100 USD for a downpipe ( I think that's what it is called ) from aftermarket group does not justify messing around with welding a new sleeve.

This is what *should* be there

https://www.ecstuning.com/b-genuine-...ch/1k0253141h/

But it could've rusted and they just welded it instead of buying one


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[Theiceman]

This is what *should* be there

https://www.ecstuning.com/b-genuine-...ch/1k0253141h/

But it could've rusted and they just welded it instead of buying one

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hmm thanks Eric

That's what have left over from my A6 and thought great !! until a crawled under the car and saw you are right some F'er just put a sleeve on and welded it up ...

not the end of the world though . I will cut it off upstream of the welded sleeve, cut a chunk off the replacement downpipe and put the sleeve clamp on .. its not like im entering a concour event.

[canadianA4B7]

This is the best low cost method. In fact Im gloing on my 3rd flex pipe with my TT DP now.For some reason I keep blowing these out

Grab an interlock flex pipe. They are much much much better then strictly woven units. I've used 3 or 4 from eBay no issues.

[Theiceman]

hey Eric

I went to the internet and saw this ... ( not a Jeremy Clarkson moment )

https://www.ecstuning.com/b-ernst-pa...k0253141m~ern/

my confusion lies not in the price , but in the size .. now im not sure if im looking for 55 or 60 mm to connect downpipe to centre muffler.

[pezgoon]

hey Eric

I went to the internet and saw this ... ( not a Jeremy Clarkson moment )

https://www.ecstuning.com/b-ernst-pa...k0253141m~ern/

my confusion lies not in the price , but in the size .. now im not sure if im looking for 55 or 60 mm to connect downpipe to centre muffler.

Ya I had seen that too... honestly I just picked whichever looked the closest but I have a set of calipers here at work and I can measure it for you and see what size it is before it gets hot on the way home

Edit: 55mm for sure, I went to 60 and that was quite a bit bigger than the pipe

Oh and I also thought the price was quite ridiculous hahaha, 60$ for a fcking clamp??? Common Audi.

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[Theiceman]

Okay thanks for doing that Eric .. we are all good .. I just got my order in for a downpipe, gasket, clamp , and a few other odds and ends that I am pretty sure are going to break next. Looks like im going to get dirty in the next couple of weeks.
I can see how these cars could be frustrating for those who hate working on cars or always have to go to the dealer. But I do have to balance that with consideration the car has 270,000 km on it by now and some other cars would simply have been just thrown away by now.

Now I have to get back with my popcorn and see what your stalker has to say next..

Thanks again

Clive

[pezgoon]

Okay thanks for doing that Eric .. we are all good .. I just got my order in for a downpipe, gasket, clamp , and a few other odds and ends that I am pretty sure are going to break next. Looks like im going to get dirty in the next couple of weeks.
I can see how these cars could be frustrating for those who hate working on cars or always have to go to the dealer. But I do have to balance that with consideration the car has 270,000 km on it by now and some other cars would simply have been just thrown away by now.

Now I have to get back with my popcorn and see what your stalker has to say next..

Thanks again

Clive

No problem sir that's what I do. I definitely agree, mine is severely young by many standards and I have had some issues that you just wouldn't expect, it's tough because I have to remind myself that it is still 12 years old even with such low mileage (49k). I couldn't imagine owning one without doing the work myself, I can easily see why people would be turned away from the brand for reliability issues.

I couldn't imagine constantly going to a shop for a 50$ part here and there that costs 500$ cause it's behind six different other things lol

Let's hope everyone stays civil and there isn't much of a show anymore. At least with me involved, I'm not the combative type, it really bogs me down


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[Theiceman]

The down pipe and resonator are just clamped together. The bolts should be able to be impacted off

I checked mine. PO put a sleeve on and welded it up. Grrrrrr



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[pezgoon]

I checked mine. PO put a sleeve on and welded it up. Grrrrrr



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:O ouch, he didn't wanna pay the 60$ for an Audi one hahaha


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[Theiceman]

:O ouch, he didn't wanna pay the 60$ for an Audi one hahaha


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yeah so it looks like ill be doing an Audi version of a bowel resection.