What ever is causing the rattle must be fixed as this will set off the knock sensor and kill your power. Try spacing the lower tie bar like everyone has suggested and if that dose not work, then remove the test pipe and inspect the inside baffle for damage.

 

My bad, thats what I meant, the TIE bars. Thanks bro!

 

I have the same DP as you.

Just lower the front tie-bar with washers (two 1/2" washers) or replace the bolts with longer ones and use a large nut as a larger spacer.

I have two layers of insulation and my fits without hitting, see below.

 

I don't like the Megan DP because of the sound. Mine is very raspy too. I was told it's because of the thin metal they use.

FYI.... I never had clearance issuses on my install. The DP cleared all the bars.

The only thing my exhaust rattled on was the heat shields. I just pounded them out a little and no problem. Off hand I can't remember if there were any heat sheilds around the DP or Test Pipe.

 

the gasket and flange where it meets the cat or test pipe rattles against the heat shield above them i just cut the heat shield off near that area. if its the bars get longer bolts and washers for spacing.

 

Sounds like someone had a nasty leak. Mine is not raspy at all it is LOUD and I love it. My whole exhaust is megan from the block back and the sound is ftw.

 

i meant bending the hangers. maybe your hanger was off when they shipped it. i know that happens sometimes.

not sure what to bend it with...

 

We've checked, reinstalled and checked again. No leaks.

 

just lower the tie bars with washers or buy the kit from buschur racing

 

Thanks for all the ideas guys! I will keep them all in mind as I work to rectify the problem.
I forgot to mention that the car has swift lowering springs, so that may be the cause of it not having enough clearance for the sway bar.

 

UPDATE: So you were right. It was hitting the heat shield exactly were you said. I just bent it back and that was it.

Thanks for all the suggestions guys, I appreciate it!