Exhaust Mystery

[Bigfish]

04 RX-1 with approx 14K km, original stock exhaust. I replaced the donuts towards the end of last year, and have barely put 1K on since then. All was good after the change, no excessive noise and back to stock sound.
This past weekend I noticed that the exhaust was a little noisier than usual and by the end of the weekend it was extremely loud.

Pulled it apart and checked the donuts, they still look like new, and no visible cracks in the pipes (as much as I can see without removing them). Put it back together with exhaust sealer on the donuts, but it is still noisy. I did the glove test and it didn't stall out, so there is a leak somewhere, but I can't locate it. I really don't want to pull the entire exhaust out, as the rear section is a mother to come apart and I don't see any way of forcing apart without cutting it.

Is it possible that the bellows are cracked? Has anyone had them crack? I have not been able to find any reference to them breaking, but there is always a first time. Also does anyone have any suggestions on how to remove the rear section of the exhaust without destroying it?

Good job it's going to rain this weekend or I would be totally P.O.

 

[YammyRX1]

When one of my donuts was bad I noticed black soot around it on the heat shields- did you notice any areas that had black build up around the bellows? Maybe drop the rear of the skid and run your hands around the pipes and look (and listen) for cracks?

 

[JROCK]

Ive had to replace a broken bellow/front pipe on my rx-1! Had 21000 km on it when it happened.

 

[Bigfish]

Well I ended up taking the whole thing out. Only took 20 mins, 2 guys, 4X4 wood block, 5 lb hammer, and 4 beer!

Placed the wood block aginst the front of the muffler, and smacked the wood block with the 5 lb hammer for 20 mins before it moved at all. Still have not found any obvious leaks.
so I will start pressure testing the various pipes today.

 

[Bigfish]

Well I found the leak, it was at the exhaust joint under the seat!
The short two-into-one pipes had a number of pin holes under the gasket for the exhaust pipe. I replaced the gaskets and machined a sleeve to fit inside the two-into-one pipes, re-assembled and no more noise!

Good to go for another 15,000 km

Fish