In 2015, I bought a Bosal complete exhaust (minus exhaust manifold) and installed the catalytic converter, resonator and muffler. I shelved the front pipe and the short piece that the o2 sensor connects to because I didn't feel like messing with the o2 sensor and the original parts seemed fine. In 2016, the resonator failed at the flex section, so I replaced that part again. My car hasn't been driven that much since because it's been a work in progress. I'd say about 15,000 miles.

Fast forward to today. I removed the front pipe to get a the oil pan and I think...maybe I'll put in that never used Bosal front pipe and short section that I neglected before.

I take out the original, and no... the original may have surface rust but is otherwise solid. That never used Bosal piece looks so crappy at the welds & hangers that I'll never use it. Furthermore, the flange on the Bosal catalytic converter is trashed, that I might just put back on the factory catalytic convertor, which didn't really need to be replaced in the first place--I really just thought I was doing myself a favor at the time.

I'm showing pics of the rusted out Bosal catalytic convertor flange, and also a side-by-side comparison of the Bosal front pipe and factory front pipe. That Bosal has been rusting out just sitting on the shelf. :/

I know people talk about various exhaust systems looking for throaty sounds or whatever--I'd like one that holds up and doesn't make noise. While I continue my search, I give you this:


The not so old flange on the Bosal catalytic convertor disintegrating.

The factory exhaust (24 years old) has light surface rust, but never used Bosal is rusting at the welds and flange.

Factory hanger & flange look great... Bosal hanger and flange is covered with rust. Welds are tragic on the Bosal.

 

Thanks. I have heard similar accounts. Glad I never bought one.

 

Ive not done the bosal (I have a wagon and cant find stuff affordably from the b-pipe back) but the Walker stainless steel stuff seems to have held up over the last 4 years.

 

Thanks for the post--I recently did an exhaust replacement but for utility purpose (catalytic converter was stolen), so I chose parts on cost basis. I ordered from Rock Auto, but I'm not even sure who made the parts. I'll have to check now.