034 Motorsport Exhaust Fix

Took my broken 034 Motorsport exhaust mid-pipe to a shop to have them weld the reducer back onto the catalytic converter.

034 Motorsport Exhaust Mid-Pipe
034 Motorsport Exhaust Mid-Pipe

While fixing that weld they noted that two other welds were cracking, making three out of four welds on the cats bad.  They re-welded all of them.

034 Mid-pipe repairs
034 Mid-pipe repairs

I’m disappointed with the quality of the work put into this exhaust, in light of how expensive this product is I’m further disappointed.

EGT Model Accuracy

With stock K03’s, fueling, and MAF sensor the EGT model had proven to be a close match to the readings recorded via the full range RS6 EGT sensors on my car.

Stock tune on dyno:

K03 Stock Tune
K03 Stock Tune

 

Nefmoto community tune on dyno:

Nefmoto Tune
Nefmoto Stg2 Tune

 

NVR tune on dyno:

NVR Stg2++ Tune
NVR Stg2++ Tune

 

With my conversion over to RS4 K04’s, RS4 MAF sensor, and Bosch 72# EV14 fuel injectors I looked once more at how the modeled EGT’s compared with the readings from the RS6 EGT sensors.

K04 Stg3 tune on Street:

Audi B5 S4 Modeled EGT's vs Measured EGT's
Modeled EGT’s vs Measured EGT’s

 

With this setup on the street the modeled temperatures are becoming less accurate.  The mid-range modeled temperatures exceed those recorded by the sensors.

Ugh. Step backward.

I was out the other day doing a pull when bang…  braaa (very loud exhaust).  “What the heck was that?”  My first thought was a v-band clamp holding the mid-pipe to the downpipe let go and the exhaust separated.  I brought the car back to the garage and took a look underneath:

mid-pipe-separation-1

Oh, that’s not good.  Something on my 034 Motorsport exhaust system failed.  I detached the mid-pipes for a better look:

034 Motorsport Exhaust Mid-Pipe
034 Motorsport Exhaust Mid-Pipe

A clean break right where the reducer attaches to the catalytic converter.  Great, car is down and now I need to find a shop to weld it back together.