Thermal R&D exhaust on lowered '25 LOBO

[insaniti]

I bought the Thermal R&D exhaust due to youtube clips and threads from this very forum. Was super excited to get it in and installed...but unfortunately, when it arrived and got installed, the excitement stopped. Talk about a fitment nightmare... It was first installed in my driveway, with the LOBO up on ramps. And while the installation was indeed quick, it needed to be adjusted several times. No matter what I did, the rear section, where it passes over the rear diff, just hung REALLY low. It costs me 4" of ground clearance, and on a lowered LOBO, that's ground clearance I can't give up. Especially since I drive this thing for a living.

Anyway, I chalked it up to me not having it aligned properly, threw it up on ramps again a few days later and made some more adjustments. No matter what I did, the results were the same. So when I kept getting pestered by "shop" to review my purchase, I gave it a 3 star review. "Looks good, sounds good, fitment is a nightmare" Which prompted a very rapid response from Thermal asking for me to reach out with further details.

I contacted them with all the details, how many times I adjusted it, the issues I was running into, my experience level installing exhausts, etc. They replied and asked for pictures, which I sent out immediately. I then took the truck to my buddies shop and we put it up on the lift for more pics and more adjustments. No matter what we did... rotated the muffler, rotated the midpipe, put new rubber hangers on... every time we let the tension from the stands off, the exhaust went right back to where it started. I sent all this information to Thermal, and their reply was the muffler needed rotated upward and the steps required to do so. All of which we had already spent an hour doing.

So needless to say, I'm not particularly THRILLED with the exhaust fitment (it's also pretty quiet and tame if I'm being honest). So the question is, do me and my buddy hack this up, rewelding hangers, possibly re-bending the exhaust section, and doing anything we can to make an $800 exhaust fit like it was supposed to? Or do I chalk it up to a lesson learned, list the exhaust on here for someone with a non lowered maverick and buy the Borla like I should have to begin with?

Here are some pics for refernce

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[Johnkn]

Is this the system where the final section fits ...inside... the section in front of it?


Good luck


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[insaniti]

It's all butt to butt connections with compression clamps, or as I like to call them, slip clamps because that's all they do is slip.

 

[Johnkn]

It's all butt to butt connections with compression clamps, or as I like to call them, slip clamps because that's all they do is slip.

WOW. So the sections don't actually slip into each other then clamp?

Butt connections are great when used in V-Band applications. .

Good luck....


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[insaniti]

WOW. So the sections don't actually slip into each other then clamp?

Butt connections are great when used in V-Band applications. .

Good luck....


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Correct on all accounts, including the good luck lol

 

[Johnkn]

Correct on all accounts, including the good luck lol

My only words of encouragement would be to do what you need to do to fix the (overall) issue, don't just settle for something that you're not happy with.

Otherwise it will live rent-free in your head every time you drive or think about the truck..

Keep us posted...



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[johnny99]

Sell it and get what you really want. Ya been through so much BS already, you wont be happy until you get the timbre you want.

 

[EVH5150]

I love everything about my Thermal except for the slip joints and band clamps. I've installed a dozen or so cat-backs over the years, and I've never had one that used butt joints and "slip" clamps. It does sound GOOOOOOOD though.

 

[insaniti]

It sounds good when I can actually hear it, but then I'm not sure if I'm heading the exhaust or leaks from the clamps lol. It'll go up on market place and here shortly. I ordered the borla system. Should be here middle of next week.

 

[insaniti]

So the borla came today, turns out it is a cut install as well...HOWEVER, fit is PERFECT. Sound is exactly what I was lookin for, subtle during normal driving, loud when you get on it, sound is sooooo good.

But I'm not going to crap on thermal here, they did reach back out after a few back and forth emails and offer a complete refund. Just waiting for the next step, it's currently boxed up and ready to go back.

 

[Chops]

All our Maverick EB’s have the exhaust pipe over the rear differential. Makes for easy install - but less ground clearance. Here is a picture of my Borla. It has 3 inch tubes instead of the 2.25 OEM so a tad less ground clearance. There are short side exit aftermarket systems that would not have to be routed over the diff however.

 

[Johnkn]

So the borla came today, turns out it is a cut install as well...HOWEVER, fit is PERFECT. Sound is exactly what I was lookin for, subtle during normal driving, loud when you get on it, sound is sooooo good.

good for you!

I have Borla‘s on my Raptor R and Bronco Raptor. Due to the active exhaust the Borla systems on those are $$$ but fit and sound are great!

Congrats, never settle….




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[insaniti]

All our Maverick EB’s have the exhaust pipe over the rear differential. Makes for easy install - but less ground clearance. Here is a picture of my Borla. It has 3 inch tubes instead of the 2.25 OEM so a tad less ground clearance. There are short side exit aftermarket systems that would not have to be routed over the diff however.

I understood I would lose SOME ground clearance, but the thermal didn't come close to the rear diff, i could put my first in between the pipe and rear diff. Losing another 4" because it just hung too low. My buddy and I think the hangers might have been welded on wrong, like they shifted in the jig before they were welded. Either way, I'm happy now.

Which borla do you have? The type s has 2.5" piping, which one has 3"?

 

[Chops]

I understood I would lose SOME ground clearance, but the thermal didn't come close to the rear diff, i could put my first in between the pipe and rear diff. Losing another 4" because it just hung too low. My buddy and I think the hangers might have been welded on wrong, like they shifted in the jig before they were welded. Either way, I'm happy now.

Which borla do you have? The type s has 2.5" piping, which one has 3"?

I have the type x - but should have installed the type s like you did. Type X is way too loud for me. I discussed ad nauseam in a separate thread…

 

[Cancunbadlands]

I understood I would lose SOME ground clearance, but the thermal didn't come close to the rear diff, i could put my first in between the pipe and rear diff. Losing another 4" because it just hung too low. My buddy and I think the hangers might have been welded on wrong, like they shifted in the jig before they were welded. Either way, I'm happy now.

Which borla do you have? The type s has 2.5" piping, which one has 3"?

I have the Borla Pro XS with 2.25" piping

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