Hey guys,

So two weeks ago my stepdad mentioned he had a strange vibration start in his car (KE Verada), I told him to swing by my place next time he was out so I could check it out. Remembering the many threads I had read where the baffle plate inside the exhaust would rattle loose I went looking and sure enough thats where the sound was emitting from. Told him we need to sort it asap.

2 weeks pass...

I get a call saying then noise is suddenly a lot worse, so I wander up to have a listen - using the old long stick as a stethoscope with the car on ramps I rule out loose heatshields etc - looks like surgery it is.

So car on ramps, undo heatshields, manifold to Y-pipe, bolts on either side of the catalytic convertor, inside disconnect the o2 sensor plug near the ECU (2 screws to access) and push it through the floor, then drop the exhaust. Externally I see two broken welds so definitely on the right track.

VIEW IMAGE (http://i48.tinypic.com/2qxoxkx.jpg)

Cut the exhaust in half just after the baffle and there it is, the wobbly baffle.

VIEW IMAGE (http://i49.tinypic.com/2s6vy93.jpg)

Drilled out all the welds, prepped it all and welded it in there.

VIEW IMAGE (http://i50.tinypic.com/35d16qa.jpg)

Welded the exhaust back together, tidied up the welds and before putting it all back together cleaned the o2 sensor, hollowed out the cat (was cracked and yucky). Crawled back underneath, put it all back together (wirebrushed and RP7'd everything, made it much easier) and started it up - ahhhh, beautiful :)

Wow, good work. Obviously you're handy with a welder!

thanks for the pics mate, i have read about this baffle coming loose before , i know now what to look for

That's awesome info and pics. Thanks Mate, that rattle has been driving me nuts for a long while..
Everytime I put my foot on the gas I cringe.. now I can sort it .
Cheers

Great work, will perhaps move to DIY section when I get a chance

Yeah I had read about it a few times, knew where it was but had never seen pics - pics are good, give people an idea of what exactly it is, how it's attached and how to repair. Was relieved when it was something "so simple", exactly what I thought it was.

The baffle was cracked right along the weld internally, an easy two-person job with the right tools and prep. If you don't have a welder you can do all the removal, and cut the exhaust in half (hacksaw) then take to your local handy bloke to weld, then re-assemble.

I removed the cat to inspect, since they only have a limited life-span I wasn't sure what I'd find but this one was cracked right through the honeycomb top to bottom in a few places, thought better to hollow it out now than to have it collapse and block the exhaust.

Mine let loose and ended up inside the Cat :(

i got 3 pieces out
http://i556.photobucket.com/albums/ss8/MightyMag_Photos/cat.jpg

I was just about to remove the exhaust and take it to the local welder guy. Then I decided to take off the uppermost heat shield first, in case that was the culprit.
Well that was the problem solved.. I would never have thought.. but there you go.

Yep, thats why we removed the shields first to rule out a heatshield rattle before getting right into it. Glad you sorted yours martin ;)