porsches4ed (APR S3)

If some of you saw my recent posts you are aware of my APR/Random Stage 3 cat that cracked. This is the second time it happened to me. APR sent me the new cat overnight. The tech at TicherAudi in Silver Sping Maryland said he replaced 4 others with the same problem after approx 6000-7000miles. This time the turbo flange came completely apart after 8000miles.

<img src="http://pictureposter.audiworld.com/24446/dsc02467.jpg">

the whole cat was rattling back and forth just the 5 bolts were holding it in place

<img src="http://pictureposter.audiworld.com/24446/dsc02468.1.jpg">

as you can see when it was removed it was in 2 pieces.

<img src="http://pictureposter.audiworld.com/24446/dsc02475.jpg">

<img src="http://pictureposter.audiworld.com/24446/dsc02473.jpg">

I took the new cat to a local shop in my area TempestRacing in waldorf, I told the tech there I wanted the outside TIGwelded. As soon as he held it he said,"this is cheap steal I can tell it is made in japan it will probably crack again but I will weld it for you." He then showed me the difference between US Grade T304 and the one I had. It is a thicker mil and feels smoother. $50 dollars later...

<img src="http://pictureposter.audiworld.com/24446/dsc02469.jpg">

like a stack of dimes, this guy makes custom exhausts, his work is top notch. on the turbo flange there were gaps because the flange did not meet the piping as it should, it was not contoured like the flamge so he has to double up on the weld there.

<img src="http://pictureposter.audiworld.com/24446/dsc02470.jpg">

It only happens on the turbo side because of the gaps, the exhaust side meets to the flange perfect

<img src="http://pictureposter.audiworld.com/24446/dsc02474.jpg">

Random sucks and APR said they are aware of the problem. Hopefully it wont crack again

<img src="http://pictureposter.audiworld.com/24446/dsc02471.jpg">

Dont get me wrong I can say nothing but good things about APR the turbo kit is super, customer service is excellent, THANKS KEITH!GREG! and CHAD! out of all of the APR kits out there Im not sure how many others have had the same problem to make it a big issue RANDOM probably sent out a bad batch and I got 2 in a row.

Steve_Ag Arrow

hope it was welded perfectly so your whole downpipe is not going to rattle or rub on something

JAFO

but he's right about it cracking again.

porsches4ed (APR S3)

nothing is rubbing or rattling so far

JA4T

The only other way to increase the structural integrity is to sleave it next time with a harder steel tube. In a way that is rigging it, but it would work. The best thing would be for APR to discontinue that part and send the whole idea back through R&amp;D.
J

ModifiedA4

id make sure the exhaust is hanging right.

boostedfun

excessive drivetrain movement has lead to many stock cats breaking the same way.

Chard

They sent me a new cat (not overnight) and I still have it off the car. I wonder if I should have the welds reinforced before having the new cat installed. The cat that cracked was their old version...supposedly I have their newer version now. It's definitely a lot smaller than the original one.

M.S.G. Homey2

Still think there may be a hanger issue. If anyone else has one and is sending it back to APR, I could do a full failure analysis on it after work hours and find out the root cause.