Kaymar rear 80 bumper: exhaust interference solution?

[e9999]

So, still working on putting the Kaymar on the 80.
The exhaust pipe is touching (hard) the Kaymar wing support just downstream of the resonator.
Did a search and saw a couple of mentions about possible solutions such as cutting off the resonator - which I'd rather not do- and some short reference to futzing with the rubber mount for the resonator. Crunching the pipe will likely not work as it's too close to the resonator. And I'd have to grind 1/4" or so from the wing support which I'd rather not do either. So I'm still unclear as to how best and optimal way to tackle that.
Could somebody elaborate a bit more on how they solved that issue if that was also the case for them?
Is it possible to relocate easily the pipe (move it sideways to the outside) as a DIY job?
TIA
E

 

[Giulitto]

I have the same issue with my kaymar bumper. It rattles against the bumper during start up and going over washboard or any bump. I just got used to it.

 

[Bikeman]

If you cut the resonator off, you will get an annoying whistle during acceleration.

If you leave it on, it will get crunched!

Solution: custom cat-back with a turn-down.

 

[FirstToy]

eric,
take it to a muffler shop. they can re-route the pipe anyway you want and keep the resonator- it's a very simple job and won't cost you much at all.

 

[Nay]

If you cut off the resonator, people will think you have a turbo under hard acceleration. Well, at least until you don't actually get up and go . I honestly don't notice it unless I pay attention, and my MT hum is providing a nice white noise cover up to most other noises anyway.

Having said that, I agree that a muffler shop can handle this for low $$$ - as long as your spare is removed you've got a ton of room to work with, and relocation will save you from the eventually trail relocation. It's one of those things that will cost less to do now than if you damage it and aren't willing to just cut it off.

 

[e9999]

had good luck with my resonator so far, it's still intact...

Bikeman, I'm in the PRK, can't cut some things off and get away with it here...

FT and Nay, yup, could do that. I'd rather do something myself, though. Gotta look at the resonator hanger mount and see if I can tweak that...

Took it for a spin, does make quite a bit of banging at idle, not so much underway...

 

[SOCALFJ]

I have the OEM exhaust setup and a Kaymar.. and i dont have any problems...Did i get lucky?

 

[nakman]

Mine was rattling against that wing support, so I just pipe clamped it to the bumper where it was rattling. Has been nice and tight for probably 3 years now, no issues..

edit: here's a pic

 

[e9999]

Mine was rattling against that wing support, so I just pipe clamped it to the bumper where it was rattling. Has been nice and tight for probably 3 years now, no issues..

edit: here's a pic

thanks, interesting idea...

the thing, though, is that you then have a rigid mount essentially, which is what they are trying to get away from with the rubber mounts and all, no? because of vibrations, thermal expansion etc. That OK?

 

[nakman]

it's ok with me..

 

[Brentbba]

I have the OEM exhaust setup and a Kaymar.. and i dont have any problems...Did i get lucky?

Yes you did. Mine rattled at idle much like Eric describes for several months. Now it just rests hard against the wing support and doesn't rattle any more. I'm leaving well enough alone!

 

[scdunn]

I had the same issue with my Kymar install and tried to live with it but coudn't hack it. I replaced the 4 bolts that hold the isolator mounting bracket to the frame with longer bolts that must of come off the OEM bumper. I shimmed the bracket with 2 oversize nuts per bolt, which moved the tail pipe over almost 1/2 inch, which was plenty to stop the rattle and it doesn't seem to stess the isolator overly much.

 

[Atoyot1031]

Mine has a custom exhaust that stops short of the bumper end ( to avoid crushing) and is turned down at the tip. Works great, and after driving for a while that PS corner on the Kaymar is perfect for cooking up some eggs!

I'll try and grab some pics of it for you.

 

[george_tlc]

Old thread, but mine rattled when I got my kaymar ~10 years ago. I just cut/bent one tab a little and also made a 3/8" spacer to move/center the exhaust in the kaymar cutout. Never rattled since. The spacer sits between the chassis and the rearmost exhaust bracket (near the resonator).

Add spacer:

Cut/bend tab:

Finished result, centered exhaust:

cheers,
george.

 

[e9999]

excellent, that's what I was talking about!
Will go have a look and see which of the brackets etc these are.

 

[theferg]

I've had my kaymar on for about two weeks now and all seemed well for me--never noticed anything like this. Then I read this thread last night and go out and check it out this morning and waddya know?--mine rattles a wee bit.. Argh.

-Ferg-

 

[e9999]

I've had my kaymar on for about two weeks now and all seemed well for me--never noticed anything like this. Then I read this thread last night and go out and check it out this morning and waddya know?--mine rattles a wee bit.. Argh.

-Ferg-

yesss, the dreaded Mud syndrome...

 

[Romer]

I pinched the exhaust a few time with the slee while wheeling. So I changed the piping from the nuffler back to 3" and after it went over the crossbar added a glass pack to further reduce the sound. The exit is still under the truck where it can not get mangled with no resonator. Sounds a little louder, but I like it.

 

[reffug]

leave it to George as usual to have already been there done that and conquered the problem.

 

[maxboost82]

lower the pipe a bit .25" and put a stiffer hanger on it. (southern hanger) would be the term i use in this profession.