replacement exhaust - Bosal - Just say No

[JohnnyTooBad]

My original factory exhaust rusted out and needed replaced to pass the annual VA state inspection. This is just a daily driver, no mods, and I have a slew of kids. So I went cheap and got a Bosal system (everything after the flex pipe). Only cost $350 for the center and both mufflers

Simply put... POS

1) The factory missed about an inch of welding on the center pipe where it meets one of the middle "mufflers" or whatever that is, causing back pressure and a P0171 and P0455 faults.
2) The pipes are not the same size as the OEM, so mating the center pipe to the front/flex pipe, I had to make a gasket to get a good fit
3) The pipes for the pieces they sent were not sized properly. Where the right muffler pipe attaches to the center pipe, the size was so far off, that could fit 1/16 gasket all the way around, but the left muffler fit properly onto the center pipe
4) The oval exhaust tip on the right muffler was not welded properly to the tail pipe, causing it to be rotated enough to be noticable
5) The exhaust system so f'ing loud inside the cabin that my 10 y/o son says it hurts his ears. It's obnoxiously loud inside the car when you accelerate. Cruising is ok.

Just don't do it.

Now, I'm going to call Rockauto and see what kind of remedy I can get. I'd like to just return everything (on their nickel) and go with something better, but I'm not looking to jump up to a $800-$900 system like the one from EuroParts. I'm just looking for OEM grade. I looked up original Audi parts, and that would cost $2000. I need to figure out what I can get, hopefully for under $600, that's better than this Bosal crap, assuming I can be made whole by Rockauto. If they won't play, then I don't know what I'll do. Damn, I'm pissed

[B-Time]

Get a used stock system.

[ADCS]

I just installed a Bosal downpipe for a TIP 2.0t and the fitment was pretty bad as well. The angle of the pipe after the flex pipe is incorrect so the exhaust clamp does not fit correctly. Easily fixable and for $65 I can't complain.

[67Twisty]

Rockauto is terrible for returns. You'll be out the shipping both ways, the original cost plus the return. And sometimes they flat out refuse the return if it shows signs of being mounted. They often have great prices on general maintenance items and I use them a lot in that regard, but no way for items like exhaust systems. Agree with the suggestion on a used system if it's relatively new and you're not buying into drone or poor Fitament. Usually best if you can find someone local with similar system for a test drive before you buy.

[BenMTL]

Look into a Magnaflow system, 16001 is the code/model for our cars....6 speed Quattro manual at least. Better sounding (IMO) and same quality as those $800-900 other brands but cheaper...

Magnaflow is known around the American muscle scene and that was the (deeper) sound I was going for anyway...Great quality and fitment as many us on this forum can attest to.

[ADCS]

Rockauto is terrible for returns. You'll be out the shipping both ways, the original cost plus the return. And sometimes they flat out refuse the return if it shows signs of being mounted. They often have great prices on general maintenance items and I use them a lot in that regard, but no way for items like exhaust systems. Agree with the suggestion on a used system if it's relatively new and you're not buying into drone or poor Fitament. Usually best if you can find someone local with similar system for a test drive before you buy.

I have had to return one item to RockAuto, a radiator, and it was flawless. They refunded the item + shipping/duty and gave me a shipping label for return. I wasn't expecting that being that I am in Canada but I was pleasantly surprised. Needless to say they have and will continue to get my business.

[JohnnyTooBad]

I have had to return one item to RockAuto, a radiator, and it was flawless. They refunded the item + shipping/duty and gave me a shipping label for return. I wasn't expecting that being that I am in Canada but I was pleasantly surprised. Needless to say they have and will continue to get my business.

I was going to say, I think they are being very good about the return. I also returned the clamps, which are not reusable, and I got the $1.88 (2 clamps) and the $5.70 original shipping refunded already. So they do refund the shipping. I already have shipping labels to return the junk parts (no cost to me), and I ordered a Walker system, with the higher end mufflers. Plus, the Walker is all stainless (not polished) instead of aluminized mile steel. We'll see how that fits and sounds. The total, with shipping was $520 (there's a 5% off coupon you can easily find on line). If it's still crap, I'll look into the Magnaflow and the OBX, which has some decent reviews here. But I'm really not looking for a race/tuner sound, and I want it quiet in the cabin so that I I don't hear the engine when I'm on a road trip listening to music. This is my ski car, so it gets lots of longer trips, as well as my daily driver to work.

[Charles.waite]

I put a Bosal DP on my b6 before selling it and the fitment was spot on.

[ericw.]

2) The pipes are not the same size as the OEM, so mating the center pipe to the front/flex pipe, I had to make a gasket to get a good fit

All of that sounds like crap, but #2 above should be expected. The OEM pipes are some stupid measurement in the thousandths like 2.189" diameter (<probably not actual size).

[6speedman]

I put a bosal DP on a b5 passat fitment was good and quality was good considering the price.


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[JohnnyTooBad]

Just a follow-up to finish this one out.

I ordered a Walker system from RockAuto. They emailed me return shipping labels and refunded the original shipping. I got the Walker stuff on Tuesday, and installed it today. It's much higher quality. Stainless instead of aluminized steel, and all the tabs that go into the hangers are just like the original Audi stuff that has the directional tabs on them, as opposed to just being extra long with bent ends to keep them from backing out of the rubber hangers. The fitment was perfect and the mufflers are even the same shape as the original Audi mufflers. It took me all of an hour to pull the old Bosal stuff out and put the Walker stuff on. The sound is very quiet. Very original sounding. So the total cost was $140 more than the Bosal, but worth it.

On a nice side note, when I got the Walker stuff on Tuesday, someone picking the stock at RA was feeling dyslexic, and sent me one muffler with a part number 269 instead of 629. I was out of town for work until Wednesday night. I called early Thursday (yesterday) morning and they immediately emailed me a return shipping label, but said the new one wouldn't get to me until Tuesday. I looked at the order status this morning, and it said it shipped this morning with an arrival date of Tuesday. But at 10:30am, a FedEx truck showed up with my correct muffler. They over-nighted it for me. Kudos to RockAuto for that.

[LT1FirebirdSLP]

I'm going to revive this thread: Simply say NO to BOSAL.

I have a B6 A4 but the quality of work clearly breaks across all their parts. This is a brief story of the flexpipe section I purchased from them for my B6 A4 at a local NAPA.

1) The flange that bolts to the cat was obviously a universal type flange. The three bolt holes were so large that the OEM bolt would slip clear through it. Had to add an extra wide washer.
2) I'm not pro welder but the thing definitely looks like it was put together for a middle school shop project.
3) The most astonishing part: The opposite end of flex section (which mates to center muffler pipe) was shrunk down! So when used with OEM hardware (55mm exhaust collar) it doesn't fit! I'm going to end up taking some existing 55mm tubing, cutting off the shrunk down part, and welding on the larger 55mm tubing to make a proper seal with my collar.

I will never buy a Bosal product again. It's obvious I should have just bought OEM.

[Theiceman]

My bosal down pipe worked fine. Sure I had to use some fender washers but so what. At a tiny fraction of dealer cost I can live with it.
Most exhaust projects are " make it up as you go along" anyway. If you have a little ingenuity I see no issue with the product.
But I agree if you want exact match every time, nothing beats OE from the stealer ship.
Just bend over and get your wallet out

.. carry on ..


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