The rear portion of my Calmini muffler broke internally allowing the tailpipe to rotate w/in the muffler causing quite a bit of squeaking. After telling the shop that it was only a year old, I was encouraged to send it back to Calmini because a broken neck (as I was told) in a muffler is a defect. Calmini's response to me was quite interesting. I was told that the muffler was a generic $30 retail turbo muffler that was available anywhere. When I told them that a SC kit ran $270 from them they told me that "Its a value packed kit. . ." Sure $30 for a "generic turbo muffler" and $240 for pipe, hangers, and a tip. All I can say is that I'm not pleased w/ their product and for anyone considering Calmini Exhausts, visit a muffler shop and invest in a Flowmaster 40 Series. Sorry, had to vent.

Can't the shop just weld the neck up? I don't think it's a problem with the Calmini system as I've busted Flowmaster, Magnaflow and others...If it's a Truck/Offroad system, it takes a lot of abuse. In my area (Reno) all you would get for a 240-270 bucks is a low end turbo muffler and a couple of bends so I think the price is reasonable.

If you want custom, you pay for custom...my X's exhaust I just had done was $400, but it won't break any time soon.

I broke mine in the same spot soon after getting it due to offroad damage and the shop just welded it back together. I haven't had problems with that joint since.

I guess my frustration is that I haven't done any serious off-roading. . .but, as mentioned the price for a custom exhaust is considerable so what I paid for the kit isn't really too bad. . .Hopefully, if determined to be a defect, Calmini will replace it or help me out in some way. Just wanted to alert people w/ the same kit to keep an eye on that joint.

Mine broke the same way. I think it's due to the factory hanger midway along the frame not being used. I had it replaced, then had a bracket welded to the new tubing to moun o the factory hanger.

Ebay Flowmaster 40 series: 45.00$
Installed by local shop: 35.00$
No headache, no probelems: Priceless
Total: 80.00$

Did you just have the muffler installed and left the rest of the pipe intact? If you swap out to a larger diameter it should run more than that...otherwise you got one heck of a deal Mine was for 3" pipe at the Y all the way out which is why mine was so pricey (something about that diameter really jacks up the price of a system...).

3 inch pipe? Must sound great, but how has it affected your low-end torque?

Yeah, WOW 3"? It looks as though you are not SC'd, so why 3"?? 2.5 would be fine for single pipe non-sc. 3" for a sc with a single exhaust and 2.5" if you're going to dual exhaust.
I am also curious as to your low- end torque loss.

hey if i want something that sounds more aggresive, and i want a little more performance, is there a bolt on muffler that can keep the existing pipe? i dont want a chrome tip or any of that crap. i just want more sound and any extra kick in the pants possible... so is there a bolt on muffler that fits right in?

Same thing happened to my exhaust, Calamini told me it was from the northeast weather and there was nothing I could do about it. They sent me a new muffler but whats the point.

I just had my Calmini installed a little over a week ago. I haven't started off-roading yet. I hope I don't have the same problem in the future. I'll just have my the local exhaust shop do a little welding if it happens.

Take it to a muffler shop and have them put a mount for the front stock factory hanger on it. I believe CALMINI doesn't have one because the muffler is so much lighter than the factory muffler. That's quite a bit of exhaust to be hanging unsupported for 6 feet regardless of what it weighs.

No torque loss that I have noticed, and the system is pretty quiet. I did 3" because it was the closest diameter to the wideest point in the factory system. Running 33" tires a cold air intake and this system, I've been pulling away from stock exhausted, stock tired, K&N intaked X's and chattering back and forth on the radio we couldn't determine exactly what it was...but if anything, running 33's mine should run like a dog. The main reason I re-did the system was to tuck it up as far as possible PIC Sorry about the delay in replying, I just noticed.

I hear you brotha....I won the Calmini Exhaust system at GOX two years ago...It last for about 6 months....the pipe broke the same way inside the muffler causing loud noises and rotation. I brought my X to a shop to have them spot weld the muffler to the pipe..$5, cool....2 months later, it broke again, now on both ends....I wasn't even offroading during that time...took it to a different shop...$5, had it welded on both sides....well, 2 months later, right before GOX4, it broke again....I did GOX for 2 days and finally could't stand the noise coming from underneath....I took it to the Ouray garage....I had it welded again (3 times so far)...and this guy welded the crap out of it....lasted one month.

I went ahead and bought a cheap turbo muffler for $15 from Oreilly...I re-used the pipe sections from the Calmini setup....this actually lasted a year until I really did hit something hard offroading and broke the pipe inside the muffler.

So basically my $15 turbo muffler from Oreilly lasted longer then Calmini's muffler from a $250 exhaust system. At least I didn't have to pay for it :rolleyes:

Wow. Hope it works out for you. I almost bought the calmini system, but decided to go with the Stainless Gibson system for the extra $100.

Lovin' it so far.

As many have said, I'd visit a custom exhaust shop and see what they can do to help.

has anyone made a duel exhaust for the X ??

Nope, kinda pointless since there's no simple way to route it. A few have had custom ones made, search "dual exhaust" (note the spelling) for more info.

Brent

RIxterra has duel exhaust... flowmaster 50's... they come out right next to the hitch on each side. thats pretty much all i know about that...