On my way to a men's camp on Friday evening I heard the familiar exhaust rattle which normally happens when that stupid front mounting bolt shears off...

The rattling lasts till about 3000 RPM and then quiets down. This however lasted the whole rev range.

Pulled over and saw the new front strap had snapped!!! Exactly where the old one did!


Torqued and installed correctly. I mean, seriously!!! Got some wire and temp fixed it:


At the venue (on a farm) the owner turns out to be an engineer.

Pulled into his garage, pulled off exhaust, welded the strap with his fancy schmancy welder with stainless rod.
Made a little spacer to compensate for the loosness/play in the mount's bushings.

Then we saw this on the bottom of the header:


Completely worn out from heat - anyone else seen/experience this?

I think this is the reason why the torca clamp doesn't seal properly, which in turn places stress on the front muffler strap and mount?

Also saw my exhaust servo cable is badly frayed and might snap soon.

Now, on the 08 Uly, what are my options?
1. get new cable (easy to install?)
2. Can I unhook on the exhaust and bypass with Tunerpro RT as with ECMSpy?
3. Emulator?

If I get this all sorted then she is A-OK again!