Ok the headers are finally installed. Pacesetter longtube with magnaflow cats and magnaflow 22" muffler with built in x-pipe. Now the problem: if you listen to the sound clip you can hear a grinding noise thats intermitant, I CANNOT find what it is. the noise is intermittant starting at about 20mph/ 1200rpm then cuts out and starts again at about 1800-1900rpm. Noise is significantly worse while running Edge tuner, and can only be heard while driving not while in park or in neutral while stopped. Any help would be appreciated. Other than this noise the sound is GREAT and performance feels significantly improved. http://media.putfile.com/headers-with-noise

 

I can't veiw the file to listen, but your description makes me think your headers are hitting the firewall when you accelerate, or maybe their hitting your starter.

 

Ttt

 

Maybe your left a loose bolt or somthing? and its rattling arround, or your headers are hitting somthing metal.

 

I would double check your header bolts honestly - I also detect a bit of a leak under load.

Do the Pace Setters have a flange or are they clamped to the exhaust?

 

FOUND IT! No loose bolts and they are not hitting the fire wall. Apparently the sound is just so deep its causing the entire pipe to vibrate primarily at the pass. side catalytic converter. Why this happens only under load etc. I dont know but when I brace the pipe just a little its completely gone. I'll take it back monday and have them add a hanger or two and hopefully have it fixed. Big Thanks to everyone who offered help. PS Ill add some more sound clips tommorrow.

 

Good job. It's nice when a plan comes together.

 

Sounds like a faulty catalyst to me. If you get a rubber hammer and beat on the right cat, will it rattle and make that noise? The cat can break inside and rattle around and it sounds JUST like that when it does.

 

Crap! Dont say that Matt. Would that also explain why the drivers side is significantly more heat discolored than the passenger side?

 

Maybe.....if it is actually rattling and broken internally, it can cause a lot of blockage and make the exhaust go to the other side.....is there a Y-pipe between the 2 pipes before the cats? I hope it is something else a lot simpler but I have seen it happen quite regularly at work.

 

No nothing before the cats just headers. But the Pass side looks brand new and the Driverside looks like a typical cat already turned bronzish. Ill check with my exhaust shop tommorrow I hope thats not what it is I expect a nightmare trying to return it.

 

That sux what cats did you use?

 

magnaflow 54306 2.5" in and out

 

Is that an old Teal Blue 98 Custom? Oh the good ole "Paintball days"