Of two of my new foreign headers from van cafe, one had hole in weld at flange at head, which I discovered after VW dealer installed them.  Van Cafe welded up hole. Sloppy manufacturing with no quality control.

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On Aug 29, 2011, at 1:05 PM, John Goubeaux <john@UCSB.EDU> wrote:

> Guys,
> 
> This is an attempt to resurrect the discussion on what the cause of a
> rear exhaust header hitting the rear engine mount bar actually is.
> Initially I suspected having replaced the engine mounts ( that were
> maybe too thick) of the cause. I have since talked to one other person
> who also replaced their exhaust headers with the Danish aftermark model
> ( also purchased from VanCafe) and he IS having the same problem where
> when the engine's movement causes the pipe to hit the rear engine mount
> bar. It appears that maybe there was a "bad" batch of these pipes that
> do not fit quite right and the clearance between the pipe and the bar is
> too small causing the pipe to "clunk" up against the mount bar ?
> 
> Has anyone else seen this ? I also suspect that eventually the pipe is
> going to crack from the  clunking contact but not sure.
> 
> -john
> 
> 
> On 5/31/2011 5:11 PM, John Goubeaux wrote:
>> I too suspected the rear engine mounts, however I replaced them with
>> the new engine. I also got an opinion from another mechanic who
>> indicated that everything looked like it was in order. Also, because I
>> had another bad pipe and and a poorly cast collector knuckle ( all
>> same aftermarket brand) I had to return I suspected the pipe bend.
>> Maybe the new engine mounts are thicker, this would account for the
>> rear engine mount bar being closer I think ?  They did look a lot
>> beefier than the old ones they replaced ?
>> 
>> -john
>> 
>> On 5/31/2011 4:52 PM, Jake de Villiers wrote:
>>> John, I have had the Danish exhaust pipes on both my 1.9 and 2.1 with
>>> no issues at all, so I'd tend to look for worn or broken engine
>>> and/or transaxle mounts.
>>> 
>>> Jake
>>> 
>>> On Tue, May 31, 2011 at 3:35 PM, John Goubeaux <john@ucsb.edu
>>> <mailto:john@ucsb.edu>> wrote:
>>> 
>>>    So , just to follow up on this thread I determined that the "clunk"
>>>    noise I ( sometimes) hear when starting or stopping the engine is the
>>>    rear exhaust header hitting the rear engine mount bar.  I
>>>    replaced the
>>>    exhaust headers on the new engine (after marker Danish ones) and
>>>    along
>>>    with poor quality issues ( one of them had a cracked weld at the
>>>    flange)
>>>    it looks like the bend on the rear pipe comes too close to the rear
>>>    engine mount allowing it to hit the mount bar. Not sure if I can
>>>    get a
>>>    muffler guy to fix this or not but at least i know what is
>>>    causing it.
>>> 
>>>    I'm surprised no one else has had this problem as well, as I
>>>    suspect a
>>>    lot of people are using the aftermarket pipes being sold. These were
>>>    purchased from Van Cafe.
>>> 
>>>    -john
>>> 
>>>        Guys,
>>> 
>>>        I have roughly 500 + miles on a new GoWesty 2.2 engine that I
>>>        just
>>>        installed and am curious about an odd noise it makes, but
>>>        only when it
>>>        is warm, eg been brought up to temp. On startup, ie cranking,
>>>        just
>>>        before it starts and when turning of the engine there is a
>>>        small clunk
>>>        noise. Almost as if before and after  ignition takes place a
>>>        compression
>>>        sound as the engine comes to a stop. The engine runs fine and
>>>        there are
>>>        no odd noises while running only at start and stop. I have
>>>        not been able
>>>        to listen to it back at the engine compartment yet but am
>>>        planning to do
>>>        so. Nothing is loose that can explain this and maybe it is a
>>>        normal
>>>        sound and is compression on these engines? Oddly it only
>>>        exhibits this
>>>        noise when hot though. Could it be a loose head? Sticking valve?
>>> 
>>>        Logically I am being very careful to break it in properly and am
>>>        listening and watching its behavior carefully and want to
>>>        ensure that
>>>        this is not something that is going to end up being an issue
>>>        down the
>>>        road.
>>> 
>>>        Any ideas ?
>>> 
>>>        -john
>>> 
>>> 
>>> 
>>> 
>>> --
>>> Jake
>>> 
>>> 1984 Vanagon GL 1.9 WBX - 'The Grey Van'
>>> 1986 Westy Weekender/2.5 SOHC Subie - 'Dixie'
>>> 
>>> Crescent Beach, BC
>>> 
>>> www.thebassspa.com <http://www.thebassspa.com>
>>> www.crescentbeachguitar.com <http://www.crescentbeachguitar.com>
>>> http://subyjake.googlepages.com/mydixiedarlin%27
>>> 
>>