Anyone running a Magnaflow catback exhaust on their 5?

[Geeshik]

I have been looking for a suitable and durable exhaust replacement for our Mazda5. The oem pipe after the flex is starting to go where the support bracket is welded to it (where the bend is close to 90 degrees), and the tailpipe/muffler is also very rusty. No fumes inside the cabin so far, but I should be proactive because aside from the embarrassment of a noisy buzz when driving, my family drives this thing every day.

The OEM exhaust from Mazda internet suppliers is somewhere in the neighborhood of $700 for the two sections. The Magnaflow 24886 and 51886 are the numbers listed for the center section. One is standard and one is OEM grade. Standard grade is something like $383. OEM grade is more, and it has a higher percentage of precious metals in the cat. From the chat I had with a salesperson, I know Magnaflow uses 409 stainless, which is what the OEM exhaust is, so it is still prone to rust here in Wisconsin. I am hoping for something in the 304-316 range of stainless for aftermarket exhaust, but the OEM version lasted 9 years, so it may be a consideration, but it isn't ideal. I would never consider aluminized steel because in my experience, it lasts between 3 and 5 years where I live.

I was wondering if anyone has a Magnaflow system or if they have a recommendation comparable weld/bolt in application for cheaper? The outlet on the flex is 2.5", so I would like to keep the rest of the exhaust the same if possible. I believe the OEM is 2 1/8 - 2". I have a welder that works now (I ditched the Coplay Norstar and got a Miller mig), but I don't have access to any tube bending equipment.

 

[njaremka]

I have the standard grade Magnaflow cat pipe installed to our Mazda5, and honestly, it's and OK piece. It comes in two pieces, with a slip joint in the middle. It's an easy piece to install. However, it has a thin flange at the muffler connection that is already showing signs of rust. I'm not sure how much longer it will last.

If if you only need the piece to get a few more years out of the charts system, it will probably be OK for you. If you want to get 9 more years, I would fit the bill for a replacement OEM pipe.

 

[Geeshik]

Ok. It's not what I wanted to hear, but thank you for the info. I will look into other options. I looked at it today, and everywhere there was a welded attachment (heat shield, brace, etc.) added to the exhaust, there is an exhaust leak. I counted 5 leaks from after the 2nd cat/muffler section. It sounds like a buzzy piece of junk right now.

 

[Geeshik]

I took the car to an exhaust shop hoping they would fab up something for me in stainless. They were unwilling, but they were willing to throw on a walker setup for something like $400. I talked to my wife about it, and decided I could buy a whole lot of cheap systems for what the really nice ($999) 304 SS cost online. I kept more of my money and ordered the favorited components from the Rockauto site to do it myself; a Bosal 284487 resonator for about $70, and the Walker 54845 muffler. Neither component came with the springs or hardware for the muffler flange, but hey did come with the donut and the cat gasket. I had to wait after ordering springs from Mazda because they were too rusty to measure on the vehicle and determine what size I needed. I picked up the 3" long flange head 3/8-16 hardware at the local hardware store before I finally started working on it last night.

I got most of the old exhaust out last night, and painted the new exhaust with a high temp paint. (I had a snafu when my 10 year old craftsman C3 sawzall took a crap.) I was going to bolt the new exhaust in today, but the Bosal center section that I ordered is not a slip fit at all. It is a butt joint to where you cut off the exhaust after the second cat. I looked on the Rock auto website and it says to use with 096-1763 (the Bosal p/n for their catalytic converter). I was a little disappointed about that and the fact that the resonator that actually came didn't match the one in the picture. The one that came on my center section is not a nice welded resonator, but more like a cheap seamed muffler.

I spent half the day trying to find an exhaust connector for a 55mm or 2 3/8" od exhaust. The closest thing I could come up with was online and I had to order it. I ordered the HJS 357253141A 55mm exhaust sleeve on an import site and now I have to wait again. I don't want to weld this garbage to the cat on the stock side because I know I will be changing it again in a few years, and the factory cat will probably be fine.

 

[Geeshik]

So far the new exhaust is holding up well. The other frustrating thing, aside from connecting it to the stock exhaust, was that it didn't come with an exhaust tip. Trying to find one that fit the odd size exhaust was a little difficult, but I modified one from a local part store to fit.