On a recent trip to Tumut, the exhaust system on my AWD blew large holes in each of the two bends between the centre section and the muffler. The resulting racket was unreal, especially at 2000 rpm, and I had a very tiresome trip home.

Anyway, I've now had the entire centre and rear muffler sections replaced, and you may be interested to know that these parts are not easy to get for an AWD in Sydney. Genuine Mitsubishi muffler sections are in stock, but the centre section would have had to be specially made in Japan - waiting time at least 6 weeks!!!!!

Fortunately, my local mechanic had contact with a local firm that could make a new centre section from scratch, using the existing one as a guide. An after-market muffler was also available at less cost than a Mitsubishi one. Total cost of these two sections was $680. They did a great job, all the heat shields, etc fitted back easily and the car is wonderfully quiet again.

I have to admit, I didn't expect this sort of drama sourcing common parts for a locally made car, but I guess the former manufacturer must draw the line somewhere.

This sounds strange to me - for any exhaust work, I just find a few exhaust shops, get some quotes and they custom make the components for me.

If your exhaust fails again, there are cat back systems on ebay for about $400-480 and these would bolt on.

I replaced my muffler when the pipe just behind the muffler developed a hole !! Cost was about $250 for muffler, $50 for approx 80-100cm of pipe & welding and $80 for a fancy chrome tip.

Its not difficult for exhaust shops to make the parts, why you were looking for genuine is beyond me

Its not difficult for exhaust shops to make the parts, why you were looking for genuine is beyond me

I wasn't specifically looking for genuine - I was interested in at least comparing prices. But you have to ask the question, why should a custom exhaust shop be able to make a one-off copy of the factory original for less cost? It just goes against all economic sense. Why do we accept this for stuff like exhaust systems, but not other parts?

because you could argue it is a consumable item like brake pads

I wasn't specifically looking for genuine - I was interested in at least comparing prices. But you have to ask the question, why should a custom exhaust shop be able to make a one-off copy of the factory original for less cost? It just goes against all economic sense. Why do we accept this for stuff like exhaust systems, but not other parts?

Any exhaust shop can bend readily available mild steel pipes to the same spec as factory and fit them. Does not cost much to do at all. So technically, it is not a once off. Once offs are only expensive if they are moulded or cast etc and the cost of producing the mould or cast is high.

Is this stainless steel or something? I don't think an exhaust shop would charge that much for even stainless.

No, it's not stainless, I couldn't afford that.

Vlad, I know it's relatively simple to produce an exhaust system, but we're still talking about the difference between small scale manufacture and what would have been mass production when Mitsubishi made them. A standard Mitsi product should always be cheaper than a custom job. Anyway, it's all done now and I can drive the car without feeling the need for earplugs or wearing a cap back-to-front!

No, it is not considered small scale manufacturing to shape exhaust pipes. Exhaust shops have mild steel tubes of vrious diameters which they buy in bulk. All they do then is press bend it to shape. It takes minutes to shape a complete setup. I had it done in my TP Magna a long time ago. In and out of Midas in 30 minutes.

Vlad, I know it's relatively simple to produce an exhaust system, but we're still talking about the difference between small scale manufacture and what would have been mass production when Mitsubishi made them. A standard Mitsi product should always be cheaper than a custom job. Anyway, it's all done now and I can drive the car without feeling the need for earplugs or wearing a cap back-to-front!

You're not realising the real cost involved on that 'mass produced' item - To keep the machinery (or even just dies & presses) around for every exhaust built will waste space. Pre-manufactured units that sit in storage could be rusting away almost as fast as the cars they were built for.
Plus the storage space for thousands of exhaust systems for each car would cost a fortune and be a waste of space & time that could be put to better use.
The exhaust shops can't store all of those complete exhaust systems, so they'd have to sit in a warehouse and be delivered out to the exhaust shops - that means if there's none in your city, or you're in the country, you've got a 1 to 3 day delay to repair a hole in an exhaust.

Instead, each exhaust shop keeps a few meters of metal pipes in various diameters on hand and a pipe bender - easy.
Storage cost is much less, turnaround time is just the time it takes to put a few bends in a pipe, weld on a flange and a hanger or 2 and then attach it to the car. A good exhaust shop can do that in an hour.
Plus they can cater for modified exhausts, custom vehicles, etc, all the same.
If the exhaust shops just put pre-manufactured systems on, then they won't have that skillset of welding and then anyone that can turn a spanner can be given the job - then pay will be less and their care will be less and our cars won't get looked after as well.

So yeah, +1 for specialist exhaust shops in AU.
( from my on-line chatting with people in the UK, they don't seem to have the exhaust shops and getting a "back box" (aka muffler) for a unique car is just difficult and a painful experience. )

Vlad and Oggy, You've made good arguments and I have to say the exhaust shop job looks and sounds just as good as the original. I accept it's probably unrealistic to expect that Mitsubishi could keep so many variants of exhaust systems in stock for so long.

Let's just hope the parts that can't be easily made by third parties remain avialable for a bit longer. I'd like to keep the AWD going as long as possible.

I had the same issue after Xmas.
Took it as a great opportunity to go to 2.5", highflow cat etc.
Definitely helps performance.
Had to do a bit of work to deal with the vibration period.
Carpet underlay and a couple of cans of spray glue.
Gerry

Meh the guys got his car fixed and is happy, perhaps next time there's a problem take it to an exhaust shop.