Wow, we need more info on this. What the hell? How can an exhuast get that warm that it melts the bumper cover when not even touching it? I have never heard of this on any car with aftermarket exhausts.
PS. Sorry about what happened to you Stealth, I am speechless.
The GM Performance exhaust is manufactured for GM by Borla.
A friend of mine installed the ACTUAL Borla exhaust on his 2006 STS-V and it also melted his rear bumper cut-outs. He removed it and installed a Gibson exhaust which he didn't like and then installed just the regular Corsa STS mufflers in place of his stock STS-V mufflers. Paul Santiago at Corsa told him to install the regular STS mufflers in place of his stock STS-V mufflers and get a muffler shop to retrofit them to fit the car. He loved the sound once he installed the Corsa mufflers.
I contacted Greg Orlando at Borla and he said they didn't have any reports of any rear bumper melting. He told me to speak to Ted at Borla's R&D department which I did.
I urge you to contact Greg Orlando at Borla 877-GO-BORLA x. 213 and let him know. You can also call Borla and ask for Ted in R&D because I told both Greg and Ted at Borla of the problem and they both told me that there were no reported problems when I know for a fact that there is.
Ted at Borla's R&D department told me that they sell the exact same Borla exhaust part number for the STS-V to GM and he hasn't had any reports from GM of any bumper cover cutout melting. You can refer them to this thread so they can read my comments as well as your experience.
I was going to buy a Borla system for my 2007 STS-V, but after hearing of the bumper melting, I held off and didn't swap the exhaust out at all. I am still running the stock exhaust and was hoping Corsa would release one for the STS-V. If Corsa doesn't make an exhaust for the STS-V, I will keep the stock exhaust system.
I hope this info helps you get to the bottom of your bumper melting problem.
Ok, so worst case scenario, can't we get Corsa to just sell us the mufflers and tips and then get them fabbed on in an exhaust shop? It sure would be cheaper that way and maybe gets Corsa off the hook for redesigning a whole new system.
I've spoken to our contacts at Corsa and they've reassured me over and over again that they will NOT be releasing a kit for the STS-V. He tells me that the demand does not justify cost of production, especially since the kit for the STS can be adapted to work with the V series and yields good results. Sorry guys, but I've been pushing them to make something as well, but to no avail...
Just got a return email from Jim....nothing until 9/24 Hes off to Disney with his family. No promises, but there could be something in the air.
F&I, they are 15 minutes from me and I have access to the owners ear, so, there may be something if he thinks its worth his while.