Today, after buyin' a few Bud Ice's (didnt drink any beer yet), I pulled out of a driveway, and stepped on the pedal because there were cars comin', and the next thing you know, I here what sounds like a loud pop. I let off the gas, and when I stepped on it again I realized I have a "Phat" exhaust leak. Initially I figured that I blew an exhaust gasket because I was on the accelerator so much. Pulled over to check and make sure before any more damage was caused, and the pipe/flange that bolts to the turbo was disconnected. I laughed! It was easy to see because I have a cone filter installed and the air box has been removed. I will get my welder out and remove the flange and exhaust pipe and weld it together.
The whistling sound the turbo made was awesome! I have always loved that sound. This whole situation has motivated me to think about an aftermarket exhaust system. I definitely dont want anything loud, although I do love Flowmaster's, but I do want to enhance the whistle sound. As far as the muffler sound, I would like something subtle like the Infiniti G35's. Let me know what you guys think. I will update when I fix the issue. Check out the pictures.

By the way, it happened to my Silver A4 in my Signature.

 

I repaired the pipe/flange today. I will post pictures tomorrow.

 

Here are the pictures.

First I had to mark where the flange and catalytic converter meet when fixed, so that way I didnt weld it on and it wouldnt fit.

Then once I removed everything, I had to grind the edge of the pipe so it would slide into the flange.

Once I did that, I pounded it on tight.

Then I was ready to weld it.

These are the pictures of my welds. I am still learning how to weld, but this will work good enough.



I took a picture of my wifes 2001 Audi's flange because they decided to weld it from the factory. My Audi is a 1997. You will be able to tell a difference between my weld and the factories weld.

 

Here are the pictures.

First I had to mark where the flange and catalytic converter meet when fixed, so that way I didnt weld it on and it wouldnt fit.

Then once I removed everything, I had to grind the edge of the pipe so it would slide into the flange.

Once I did that, I pounded it on tight.

Then I was ready to weld it.

These are the pictures of my welds. I am still learning how to weld, but this will work good enough.



I took a picture of my wifes 2001 Audi's flange because they decided to weld it from the factory. My Audi is a 1997. You will be able to tell a difference between my weld and the factories weld.

 

looking good. Nice job man

 

Great man. I wish I could weld some things out too. I am also looking forward to get that whistling sound on my car.

 

Friend of mine in college had a Old Mazda truck, the muffler had come clean off from the engine, I swear to god it sounded like a Formula 1 Race Car.

 

This happend to me also only it seperated after the cat but befor the cat flange. it sounds mean.

But my question is shouldnt i be worried about cold air hiting my exhaust valve and burning them up? Because i was considering leaving it that way. but ive been debating with other techs and i keep getting back and forth answers.

 

Exhaust valve? I dont know of any exhuast valve other than whats in the cylinder head.

 

That is what am talking about. the backpressure sucking cold air back through the exhaust on deceleration.