So I've just installed the Injen SES exhaust and such. I've been searching the forums, found some pople with similar issues, but I wanted to post new topic, hoping for some newer answers/resolution.
Basically, the pipe/tip is too close to the oem bumper, it's not touching, but I'm thinking it may be hot enough still to melt. I've been looking online for replacement rubber hangers, no luck.
Been exploring the idea of putting in a spacer, but not finding how that would work.
Also read the bits about squeezing the rear most hanger and getting an extra 1/4 inch out of it, but what would I use to accomplish this?

ultimately, I'd like to replace the rubber hanger rather than trying to "rig" it. Anyone else come up with better fix, or way to improve on/finish the fixes above?

 

The tip is has an air-gap inside of it. I have a feeling it does not get as hot as you think. There is some adjustment that you can make at the flange-bolts. Lossen it up try to realign tip and tighten the bolts down again.

You did remove the conical seal that's used with the OEM muffler -right? That's the doughnut shaped seal that goes between the flange and the muffler.

The only seal required is the foil-gasket provided in the injen kit.

 

yep, took that bad boy out. I kinda debated on that one for a while, until I noticed the gasket that came with didn't much provide any space for it.
My brother and his father in law didnt seem too concerned by it, but they're both avid chevy truck guys so I'm a little wary there.

 

upon reinspection ... the muffler tip is now making contact to the body

 

I had the same prob as you have now. What i did is in the little spaces of the rubber hanger itself put some spacers in it. Like some little rubber blocks small pieces of flat steel what ever. Just pull down on the muffler to open up the spaces on your hanger, and shove your spacers in there till you get your desired air gap. Wrap some black duct tape around the rubber hanger where your spacers are and you are good to go.