[undy]

It sure sounds like the baffling's moving inside the housing. My original Lone Star driver's side pipe did that. I drilled two holes on the inside of the pipe (not visible portion) on each end and threaded in a couple honker stainless steel lag bolts. It "grabbed" the assembly, pulling everything tight together and it didn't rattle after that. I couldn't find any access to weld it so that was my best shot.

Dave