altonloe

I installed a new Billy Boat Fusion exhaust on my C6 Coupe. It sounds great and I love the ability to go from Wild to Mild. I do hear a drone at certain speeds, but switching to the Mild mode eliminates that entirely. And it sounds SO GOOD when you start the car and accelerating through the gears.

Now that I've had it a few weeks it seems to have developed a rattle. I hear it in both the Mild and Wild modes. It is intermittent and never seems to happen when I first start the car. But when the car and exhaust gets warmed up it rattles. I called the factory and they are sending me some springs to put on the valves (or baffles or whatever you call them). But they said this problem is new and has only been reported when in the Mild mode. Maybe they said you can't hear it when in the Wild mode. I can hear it regardless of the mode.

Anyone else seen this problem and have a suggestion?

RedVette84

Did you change the hanger straps for the increased weight? My wife's 07's stock exhaust were alot lighter than the Corsa sports she put on and she needed to change the rubber hangers.

Luster

Also, check your clamps where the Fusion ties into the stock H-pipe. They may need to be re-tightened after driving for a while.

I had one of the stock clamps that had actually stretched and I needed to add a small piece of exhaust manifold gasket material to take up the slack.

saplumr

You should also check the retaining spring clips in the center tunnel.

altonloe

The rattle is fixed. Thanks to Billy Boat for their excellent customer service!

Two things were done. There were actually two rattles! The first thing we did was to install springs on the shafts that the butterfly valves are attached to. The spring was supplied by Billy Boat for FREE. They tell me it is on all of their new shipments of the fusion exhaust. The spring removes all of the free play on the valve and stops all of the noise coming from the valves chattering.

The second thing was a bit tougher to find. The exhaust was actually growing as the exhaust heats up. It was moving back to the back of the car by about a half inch. This caused the diaphragm to contact the frame at the rear of the car. We were able to push the exhaust about an inch toward the front of the car and now that rattle is gone too.

The funny thing about this last fix is that my wife found the problem! I had looked and looked for the problem, but she just tapped the bottom of each exhaust tip when the car was hot and got the one on the driver side to make the noise. After she did that it was easy to find where it was contacting the frame. But without her, it would probably still be making noise!

AORoads

call billy boat mfr.

Surf2602

I know this is an old thread. I have the same rattle by the butterfly's, they mailed me 2 springs but I'm not sure how to install them. Could you please send me a picture of what yours look like on the exhaust. It will help me out a lot. Thanks

tennblkc6

did you ever get this issue resolved? im looking at this exhaust so i'm curious if its a widespread issue.

thanks

Surf2602

Yes the springs did the trick. I couldn't get them on for the life of me, had an exhaust shop do it. Mine are an older version the new ones supposedly have the springs already. This exhaust is one of the best mods I've done. Looks and sounds awesome. Best of both worlds. I have headers and it sounds great. Opened up it's very loud. I'm in my mid 30's anyone who says there not loud enough should get some hearing aids😁 and the 4" round tips fill the back nice

tennblkc6

this is my concern also. if they are close to being as loud and throaty in the open position as the lm2 I presently have i'll be a happy camper.
if not...they'll be in the classifieds.

okie08vette

I have them on my 08, been on for about a year and no rattles at all. They are not to loud and the ability to close them is great.

awsum97

What is customer service phone number? I cannot find the number

RC4G

I have the same issue.

Got the springs from Billy Boat support but for the life of me can't figure out how in the world you are supposed to get them on the valve shafts.

The springs are too small to open one end and thread them on the shaft and if there is a way to disassemble the valve shaft assembly to add the springs I can't see how.

RC4G

I dealt with Mike at Billy Boat. His email is mike@bbexhaust.com

RoadkingC6

I have the Fusion exhaust also, there is a rattle i hear after the car get warmed up also but i was unable to determine where the rattle was coming from, I was suspicious of the exhaust and now i'm sure i have the same issue. Thanks for this post it was very helpful and i will be contacting B&B about getting the springs.

RC4G

OK, just got off the phone with Mike from Billy Boat.

The way you get the springs on is you have to stretch out the first coil enough to that you can easily start threading it onto the exposed shaft. Then you keep rotating the spring to wind the spring onto the shaft. Once it is on you may end up having to snip from 1/2 to a whole coil off to remove the deformed part of the spring.

Additionally, Mike suggested that for folks that don't have enough shaft play to install the spring that an alternative solution is to use e-clips on the top and bottom ends of the shaft to remove enough excess play to eliminate the rattle but not so much that it adds resistance to the opening/closing of the shaft.

I'm gonna try installing the springs this weekend and see what works.