This is a Bonez DP that I bought used, but now I'm not entirely sure that it is actually a Bonez DP.

You can "fix" this by pushing the exhaust system forward, but it takes away all of the slack that the rubber hangars provide. I think that fix sucks, so I'm making a spacer to take up the extra room and I'll have a new gasket on both sides of the spacer. Longer studs will be required, too.

This all started with me buying a new HKS DP only to find out that they were on backorder (my money was refunded).

Sonny

 

I had the same problem when I installed my GothamRacing DP. I just tightened it down, it took all the slack out of it, I was afraid for a while if I hit a bump that the exhaust may shear the bolts on the turbo. However it never did, and when I took the exhaust off to check the Cat, it fit much better putting it back on, much more slack in the system and it actually rested back on the rubber mounts. Hopefully yours will work out the same.
Marc

 

My Bonez DP does not have that problem. Mine is 5 years or more old though, so I guess there is a possibility they changed the design a little.

 

Tom:

Does your Bonez DP have a strap on it that bolts to the tranny?

Thanks,
Sonny

 

I would just bolt it up. I don't think it will be a problem.

 

can't you just readjust the rubbers or install longer ones. SHould be an easy cheap fix..

 

I've already tried just tightening everything down and watching the exhaust swing forward. It does work, but it takes away all available movement from the exhaust. I also noticed that my cat heatshield was super close to rubbing in a couple of places.

Oh well...I'll fix it since it is apart now. The studs in the cat (both ends) are toast, so I need to remove the cat and install new studs.

I'll post pics of the spacer as soon as I have it. It's basically 1/2" thick piece of steel that is the same shape as the gasket.

Sonny

 

yeah that will definetly work, was it a special fab???

 

Yeah, custom job. I scanned in the gasket and sent a friend of mine a piece of 4" x 6" x 1/2" 1018 cold-rolled plate.

Sonny

 

Nope. But now that I think about it the only reason I know my DP is a bonez is because the previous owner of my car told me it was a Bonez. So I guess I dont really even know 100% that's what it is.

 

I have the ebay pipes(DP,MP) and i had to stretch my stock exhaust as well. I havent had any problems yet

 

mine also was streched a little, but not as much as your showing in that pic. at least your install is going better than mine did

 

Mine was like that and we just pushed the exhaust forward. About 8months ago. No problem.

 

Here's a rendered image of the piece getting made:



Sonny

 

i bought an ebay DP,MP from MEGAN RACING ..so far no problems.. i just put back my stock cat and it fitted right on...

 

Spacer is done. Got 2 new gaskets to go on either side.



Sonny

 

looks good, should probably fix your mounting problem

 

Gawd, a custom part, two ungodly expensive gaskets.

I remember having trouble to get the flanges to come together until I pulled the exhaust line forward in its hangers. I just hadn't pulled hard enough to get it to slide.

 

i don't have that problem either,but i also use a midpipe that was made to fit with the bonez DP on the car.

 

The spacer did the trick!

Gaskets were $6/each from Malloy and the spacer was free. All I had to do was spec it out and shoot the dimensions down to my buddy with the machine shop. The first pic shows the spacer installed. The second pic shows the hangar on the rear of the cat. Its not all stretched forward any more.




PS-Damn...looks like I got some permatex orange on the cat. Oh well, I'll clean that off today.

Sonny

 

awesome man, glad you got it finished. dont you love the sound of the turbos now? i drove mine a couple of days ago when it finally cooled down a little outside, and adding a dp seems to add a little more go. mabie its just me, but im gonna get it dynoed soon to see what kind of hp it really adds.

 

I heard those gaskets had doubled in price, and the one on the other end of the dp was like $50+.

Good for you doing that at $12. Boy I would like access to a machine shop

 

dgeesaman--some places sell that turbo gasket I think you're referring to for $80. As for the cat gaskets they are cheap.
Sonny, I just ordered a Bonez DP from Rotary Performance in Texas to go with the Bonez Hi-Flow cat I put on last week.
I had an RVM DP on but for some reason it curves up into the under-side of the car about an inch too much and would not allow for enough room for the cat to mate up with it. Additionally, I didn't like the idea of having the weight of the cat on the DP without the DP bracket that comes off with the Precat.
The Bonez hi-slow is significantly lighter and smaller--so I'm hoping the Bonez DP will solve the fitment problem I had with the RVM DP. Hoping I won't run into the spacer issue too.

BTW-anyone have this problem before or heard of this kind of a problem where a DP has too much of a bend in that it won't connect to the MP?

 

good as new $

 

Senna: I had a "Tsudo" downpipe before this one and it wouldn't connect to the stock cat at all. You had to run their midpipe to "fix" it. I sold that setup and bought this downpipe which was supposed to be a Bonez, but I don't think it is.

I don't think you can go wrong with the Bonez DP/cat combo. How do you like the cat?

Sonny