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  1. #1
    wesley's Avatar
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    Milltek snapped!!!




    Been thinking over the past few weeks my car has been under performing and that it has started to get louder. Checked all the CAI for any leaks, and also jacked the car up today to find my Milltek has snapped completely all the way round the the weld on the middle box, I couldnt belive it when i saw this, there is even filling coming out of the split! Would this cause the car to use more fuel with an exhaust leak as the last few weeks it has ate juice?
    Last edited by wesley; 11th July 2009 at 18:40.
    07 Suzuka Grey S3, Giac Extreme plus map, Autotech HPFP, VF Engineering CAI, 18" black rims,factory tints,fbmfsw,Mk 2 RNS-E,CH-LH lights.puddle lights,Bose,Shark fin, Lamin x lights & Fogs.Full TBE miltek, 09 White DIS,Buckets,LED conversion,TPMS.

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  3. #2
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    How long have you had it?!
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  4. #3
    wesley's Avatar
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    About 4 months Staz! Not good ey. BTW why wont the picture show, i have uploaded it to photobucket?
    07 Suzuka Grey S3, Giac Extreme plus map, Autotech HPFP, VF Engineering CAI, 18" black rims,factory tints,fbmfsw,Mk 2 RNS-E,CH-LH lights.puddle lights,Bose,Shark fin, Lamin x lights & Fogs.Full TBE miltek, 09 White DIS,Buckets,LED conversion,TPMS.

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    Quote Originally Posted by wesley View Post
    About 4 months Staz! Not good ey. BTW why wont the picture show, i have uploaded it to photobucket?
    Must be an error is the manufacture mate!

    Have a read of this thread: How To: Post pictures on the forum.

    But basically copy the url in the 'Direct Link' box for the photo in photobucket, then on here in the post editor click the yellow button with mountains, paste the url and click ok.
    8P2 S3

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  6. #5
    wesley's Avatar
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    Cheers Staz, pic up above now.
    07 Suzuka Grey S3, Giac Extreme plus map, Autotech HPFP, VF Engineering CAI, 18" black rims,factory tints,fbmfsw,Mk 2 RNS-E,CH-LH lights.puddle lights,Bose,Shark fin, Lamin x lights & Fogs.Full TBE miltek, 09 White DIS,Buckets,LED conversion,TPMS.

  7. #6
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    wow four month's and its snapped id be back to the garage thats quick eh you should get a replacement for nothing ...

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    Damn, no wonder they call it a CAT, looks like you swallowed one cause theres hair right by the crack, lol.

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    Cool. Although traditionally people put the pic after the text so it's a bit more logical. Not saying you have to or something, it just makes a bit more sense that way.

    I take it you'll be going straight back to where you got it fitted then?

    Why are your pubes stuck in the split btw?

    EDIT: Dammit! NHN got there first!
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  10. #9
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    Nigel LMFAO

  11. #10
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    Had my penis in the gap for measurement purposes lol!!!!! i Got it from Statller in Sheffield, Steves a top guy and im sure he will sort it out.

    Quote Originally Posted by Staz View Post
    Cool. Although traditionally people put the pic after the text so it's a bit more logical. Not saying you have to or something, it just makes a bit more sense that way.

    I take it you'll be going straight back to where you got it fitted then?

    Why are your pubes stuck in the split btw?

    EDIT: Dammit! NHN got there first!
    07 Suzuka Grey S3, Giac Extreme plus map, Autotech HPFP, VF Engineering CAI, 18" black rims,factory tints,fbmfsw,Mk 2 RNS-E,CH-LH lights.puddle lights,Bose,Shark fin, Lamin x lights & Fogs.Full TBE miltek, 09 White DIS,Buckets,LED conversion,TPMS.

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    Quote Originally Posted by wesley View Post
    Had my penis in the gap for measurement purposes lol!!!!
    No wonder you have an S3, not going to pull any birds with that!
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  13. #12
    NHN
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    Quote Originally Posted by wesley View Post
    Had my penis in the gap for measurement purposes lol!!!!! i Got it from Statller in Sheffield, Steves a top guy and im sure he will sort it out.
    Wee small then mate, lmfao

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  14. #13
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    Haha you know what they say 'fast car small penis an all that ' Lmfao!!
    07 Suzuka Grey S3, Giac Extreme plus map, Autotech HPFP, VF Engineering CAI, 18" black rims,factory tints,fbmfsw,Mk 2 RNS-E,CH-LH lights.puddle lights,Bose,Shark fin, Lamin x lights & Fogs.Full TBE miltek, 09 White DIS,Buckets,LED conversion,TPMS.

  15. #14
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    Quote Originally Posted by wesley View Post
    Had my penis in the gap for measurement purposes lol!!!!! i Got it from Statller in Sheffield, Steves a top guy and im sure he will sort it out.
    LMAO!

    Quote Originally Posted by NHN View Post
    Damn, no wonder they call it a CAT, looks like you swallowed one cause theres hair right by the crack, lol.
    Lmao! Poor cat! r.i.p
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    Quote Originally Posted by wesley View Post
    Haha you know what they say 'fast car small penis an all that ' Lmfao!!

    So a slow car means..








    Small penis, and skint,LMAO

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    Seriously, i hope they remove that and purge it properly if they weld it, or just replace it.

    I wouldn't be happy unless i knew it was gonna be 100%

  18. #17
    NHN
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    lmfao this is one of the classic threads & I like the mix of friendly humour/banter with a proper discussion, this is what makes AS what it is, fun with car stuff as well, kudos lads.

    Also knowing milltek QC they would have it back & replace I should think given they have a seriously good rep that doesnt want to be tarnished, I doubt they'd repair, just provide new & pay for work to fit etc.

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    must be a ****y batch about.my mate was looking on astra owners club yesterday and someone had a 4 month old miltek on there astra gsi with the same problem broke the hole way round the weld

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    It doesn't surprise me.

    Milltek's marketing is far better than their build quality recently.

    I've been led to believe their high volume stuff is now made in China, which maybe explains the drop in quality.
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    Quote Originally Posted by V6Pete View Post
    Milltek's marketing is far better than their build quality recently
    Well said

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    A similar thing happend to my milltek on my beetle, however mine snapped from the hanging bracket on the back box. I got tho whole back box replaced no worries. The guy I had it off was also a Powerflow dealer and he said that Milltek import a lot of cheapo steel now since the price went up so sharply last year. He reckoned the powerflow stuff he sells was just as good quality and we all know they arent the best!
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  23. #22
    NHN
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    Quote Originally Posted by mattashforth View Post
    must be a ****y batch about.my mate was looking on astra owners club yesterday and someone had a 4 month old miltek on there astra gsi with the same problem broke the hole way round the weld
    Quote Originally Posted by V6Pete View Post
    It doesn't surprise me.

    Milltek's marketing is far better than their build quality recently.

    I've been led to believe their high volume stuff is now made in China, which maybe explains the drop in quality.
    Quote Originally Posted by Lee_R View Post
    A similar thing happend to my milltek on my beetle, however mine snapped from the hanging bracket on the back box. I got tho whole back box replaced no worries. The guy I had it off was also a Powerflow dealer and he said that Milltek import a lot of cheapo steel now since the price went up so sharply last year. He reckoned the powerflow stuff he sells was just as good quality and we all know they arent the best!
    I'm truly shocked that this has been going on, got to big for themselves & farmed it out, that is not good at all, but can also see why they might have gone for cheaper steel given prices & economy, but you'd think with there pricing it wouldnt be neccessary anyway & quality of there parts, oh well it happens to the best when they become successful, cut corners & quality control.

    Lee is urs new or old beetle mate as considering buying new beetle 2nd user for the mrs cheap.

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    Quote Originally Posted by NHN View Post
    Lee is urs new or old beetle mate as considering buying new beetle 2nd user for the mrs cheap.
    New Beetle, I'm still involved with the owners clubs,I know plenty about them if you need any info. I miss it, my A3 is so dull in comparison!
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  25. #24
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    aha I might take u up on that offer mate tomorrow as looking at a tdi 110 & get my mate to map it for little extra, but wanted to know any known issues etc, I'll PM as not the thread for it, thanks much appreciated for the offer of info.

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  26. #25
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    that must be a 3 inch pipe with a multi run....I would of thought this would of held with a single run.would be interesting to hear what miltek say about it.

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    You've got a hairy gash!!!!
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    gonna ring milltek direct on monday so will update when they respond, as people say they have a good reputation so i would expect a new pipe, im not going to accept the pipe being re welded!! not when the thing cost me more or less a grand! Not sure if they will reimburse me for the pubes though!!!
    07 Suzuka Grey S3, Giac Extreme plus map, Autotech HPFP, VF Engineering CAI, 18" black rims,factory tints,fbmfsw,Mk 2 RNS-E,CH-LH lights.puddle lights,Bose,Shark fin, Lamin x lights & Fogs.Full TBE miltek, 09 White DIS,Buckets,LED conversion,TPMS.

  29. #28
    NHN
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    LMFAO, if you got burnt while measuring with your tool, then I would ring the "No Win No Pee" line

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  30. #29
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    I have had my miltek on my car for a couple years now I think and have no issues at all but in saying that I havent checked in ages so will have to get under the car and have a nosey!!

  31. #30
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    My cousin's not had any issues with his Milltek on his car and he's had it on there for 3 years now!

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    My impression is that if the tube isnt suffieciently filled with an inert gas ( purged??) the weld will be brittle. Seems to be a chinese thing as all the clone stainless manifolds suffer joint breakage dont they.

    I hope you get it sorted mate.

    Oh and on the small wotsit problem, My Mrs tells me it's not what you got, it's what she has in the bedside draw.......... LMAO
    Last edited by Broken Byzan; 12th July 2009 at 14:05.

  33. #32
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    LMFAO thats quality Byzan LMAO

  34. #33
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    Quote Originally Posted by Byzan A4 View Post
    My impression is that if the tube isnt suffieciently filled with an inert gas ( purged??) the weld will be brittle. Seems to be a chinese thing as all the clone stainless manifolds suffer joint breakage dont they.
    It's a failure, it's not chinese. I'm having a headache with an el-cheapo clone product on my work now, and guess what, it's made in the UK!

    Btw, it's not necessarly gas, quick google says that Milltek MIG welds the outside, and TIG the inside.
    source:http://pumaspeed.co.uk/showdetails.php?id=785

    There can be a lot of reasons for the crack, lets not question milltek's quality so hastly.

    Problems with the raw material beyond manufacturer's control?
    Maybe wesley hit a puddle and cooled the joint when he was driving the car on a rage?
    Bad installation/support of the exhaust system?
    The list of possible reasons (or any combination of) is endless.

    Fwiw, I sell valves to oil and gas companies for a living. They'd pay good money to make sure everything is designed/manufactured to standards and tested for possible faults. (heat treatment after welding, hardness check, pressure testing, low temp testing, inspector for everything, a 2nd inspector to make sure, and a whole lot more), and even after passing all that, failures still occur, though rare.

    Milltek makes how many thousands of kits each year? and how much do they profit from each kit? If they were to do FEA on each and every of their product, use a high safety factor for all considerations, and test the product to make sure it can survive the pressure, temp, and loadings in the worst possbile case, none of us could afford the damm exhaust.

    No disrespect to milltek or any other exhaust manufacturer, but I was told that most "research" is actually involved in test fitting the thing, and if it can be driven around fine in a car for a while, you have a new product! Maybe some companies would go to the extent of testing with a few different pipe ID, layout, or things like that, but nothing one would call a full blown research/analysis. I'd be glad to be proven wrong on this one.

    Personally, I'm surprised that so many kits survive for years. Still, I'd gladly buy a milltek and ask for a discount. Just wont expect it to last very long though. That said, I wouldnt be too happy in wesley's position too.

    Just for comparison, this is what a properly engineered exhaust should resemble, and i believe only huge factory backed companies have the money to make it happen. Remember, this exhaust is also supplied to the public, and not a one-off race part, so it has to last fairly long as well, especially when it cost a cool 20k usd.

    http://www.bespokeventures.com/blog/...lity-for-2009/



    *btw, I'm not affiliated wiht milltek or any exhaust company. sorry for the long rant, I love quality stuff that are designed by a big bunch of nerdy virgin engineers. It's just that Milltek is a business with a specific target market (i.e. common drivers who couldnt care about the last 0.5hp or few extra grams), and found a comfortable spot for quality vs price. Srsly, who here would want to pay such money for an exhaust?
    Last edited by boggysv; 12th July 2009 at 16:17.
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  35. #34
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    Quote Originally Posted by boggysv View Post
    No disrespect to milltek or any other exhaust manufacturer, but I was told that most "research" is actually involved in test fitting the thing, and if it can be driven around fine in a car for a while, you have a new product! Maybe some companies would go to the extent of testing with a few different pipe ID, layout, or things like that, but nothing one would call a full blown research/analysis. I'd be glad to be proven wrong on this one.
    Sadly, nowadays this happens more and more...exhaust, suspension, inlets etc...
    Very few are *properly* designed/engineered/tested to give what they claim to give (not saying Millteks are, or aren't...as I don't know...it's just a common thread in today's disposable society)

    I've had several of Millteks products and always found the standard of build to be very good...
    However, the fit often isn't.

    My S3 Milltek knocked when hot (on the rear Haldex carrier cradle) from the day it was fitted to the day I sold the car despite many conversations with Milltek, speaking to them directly at the Autosport Show (uninterested) and multiple complaints via one of their dealers.
    The back box also sat squint with the tailpipes square...like pretty much every other S3 8L Milltek I've seen.

    A friend of mine has an R32 (Mk4) with a different exhaust. A very fine looking and sounding exhaust...and his backbox sits squint too, you can see it when following him. "Who makes it", I ask...the answer is obvious.
    It also knocks when you give the R32 a good hammering...from the rear. Around the Haldex carrier, in fact!


    I hope you get more sucess from them than I did...although in this case I really can't see how there is ANY way they can argue with what's happened. They should replace it immediately.


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  36. #35
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    Quote Originally Posted by Ess_Three View Post
    Sadly, nowadays this happens more and more...exhaust, suspension, inlets etc...
    Very few are *properly* designed/engineered/tested to give what they claim to give (not saying Millteks are, or aren't...as I don't know...it's just a common thread in today's disposable society)

    I've had several of Millteks products and always found the standard of build to be very good...
    However, the fit often isn't.

    My S3 Milltek knocked when hot (on the rear Haldex carrier cradle) from the day it was fitted to the day I sold the car despite many conversations with Milltek, speaking to them directly at the Autosport Show (uninterested) and multiple complaints via one of their dealers.
    The back box also sat squint with the tailpipes square...like pretty much every other S3 8L Milltek I've seen.

    A friend of mine has an R32 (Mk4) with a different exhaust. A very fine looking and sounding exhaust...and his backbox sits squint too, you can see it when following him. "Who makes it", I ask...the answer is obvious.
    It also knocks when you give the R32 a good hammering...from the rear. Around the Haldex carrier, in fact!


    I hope you get more sucess from them than I did...although in this case I really can't see how there is ANY way they can argue with what's happened. They should replace it immediately.
    Funny you say about the fit , as Steve at statller had a nightmare trying to fit the exhasust and even stayed behind for over 2 hrs to rectify the problem. The exhaust didnt seem to fit properly near the back axle.It was only due to performance that i knew something was wrong with it, then after a week or so of something feeling wrong the car started to burble when switching it off. Tell tale sign of an exhaust leak. Well i will be giving them a call in the morning to discuss and wont be happy unless they replace the exhaust, i am willing to drive up to their factory to have them fit it (at there expense of course).
    07 Suzuka Grey S3, Giac Extreme plus map, Autotech HPFP, VF Engineering CAI, 18" black rims,factory tints,fbmfsw,Mk 2 RNS-E,CH-LH lights.puddle lights,Bose,Shark fin, Lamin x lights & Fogs.Full TBE miltek, 09 White DIS,Buckets,LED conversion,TPMS.

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    So Milltek exhausts are now made in China and stuffed with horse hair, this isn't good.

    What next, offshore remapping to India?

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    Got mine bk today was in at glasgow audi for its 3rd milltek!!! Welds keep breaking. Now fitted with the "new and improved" heavy duty milltek brackets and hangers. Replacing each one no probs but wot a pile of ****e the exhaust is, cant seem to get it right which is poor show from companies the size of milltek, mtm and audi???

  39. #38
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    Quote Originally Posted by paul_b View Post
    So Milltek exhausts are now made in China and stuffed with horse hair, this isn't good.

    What next, offshore remapping to India?
    With helplines based in the UK just to confuse matters worse.lol

  40. #39
    Spin140's Avatar
    6th Gear

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    An interesting thread Guys, I don't have any problems with mine to date with no knocking etc but it is relatively new so Time will tell.

    I'm pretty sure Milltek will replace the Zorst with no questions asked as obviously a manufacturing fault and I second that Steve at statller is a great guy with excellent customer service so he will provide the right solution.

    In Millteks defence and with no actual knowledge I would have to say I would have no issue where the parts are made or sourced as long as the quality control is up to the desired standard, give them a chance to fix it before condeming the product as there may be an explanation, any mass produced item is subject to the odd mishap unfortunately for any company bad news travels fast whereas good news isn't shared as often.

    Let us know the outcome in the meantime I'll keep an eye on mine .
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  41. #40
    wesley's Avatar
    Giac Extreme+!! Lovin it

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    Spoke to Milltek today and they seem to be willing to replace the exhaust, i did ask if they were made in china and their reply was NO, they said all there exhausts are made in thir factory in Derbyshire. Hopefully im taking my car up there on Thursday.
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