Exhaust: Which Would You Do?

[Tweetdriver63]

I'm about to get several things done on my 2001 base. One of them is exhaust work.

I've known the cats were bad the whole 8 1/2 years I've owned the car. When I bought it, the previous owner told me so, and that I would have regularly activating CEL with the appropriate codes. He wasn't lying. I've just lived with the need to clear the codes periodically, since the car has always run great and gotten good mileage.

I know the second cats aren't monitored, but I'm 99.999% certain they're bad too, since the main cats have been bad for the last 70k or so miles.

My plan is to keep the back box, but replace the rest.

I have a choice how to go forward. I can get used manifolds/cats from a breaker for $700 (pair) off a 2001 that has about 115-120k miles. Or, I can get new non-OEM ones for $1097 (pair). Or, and I'm definitely not doing this, I could go OEM for a ****************-ton of money.

I'm going to replace the second cats/pipes with Circuit Werks resonated test pipes.

Show of hands. Who would get the used manifolds/cats and who would get the new non-OEM ones?

[997_986]

There is also the possibility of sending in the housings and having the catalytic converters replaced with 200 cpi. That would be my plan A. The used ones have the decisive risk that they are defective or otherwise unusable. For $700 the risk would be too high for me. With the non-oem ones it would have to be clarified which cell density is installed. I do not know if 200 cpi throws a CEL on the boxster, but that would be Plan B.

[Tweetdriver63]

Originally Posted by 997_986

There is also the possibility of sending in the housings and having the catalytic converters replaced with 200 cpi. That would be my plan A. The used ones have the decisive risk that they are defective or otherwise unusable. For $700 the risk would be too high for me. With the non-oem ones it would have to be clarified which cell density is installed. I do not know if 200 cpi throws a CEL on the boxster, but that would be Plan B.

The non-OEM ones don't say anything about xxx cpi, but then again, I don't see that in the listings for any cats. They are These.

[Tweetdriver63]

I went ahead and pulled the trigger on new non-OEM manifolds/cats, but not the eBay ones. I checked Rockauto, and they have the Davico ones for $481 and $395, for a total with tax and shipping of about $992 for the pair.

I'm happy with the decision so far. I've always had very good luck with Rockauto parts. Never had any complaints about their customer service either.

Now grabbing a pair of the Circuit Werks resonated test pipes.

[Danimal]

Let us know how it turns out!

[Tweetdriver63]

I've made the appointment at my independent garage. The car goes in Oct 31st. They can take as much time as they need.

List of things to be done:

--Install new manifolds/cats, both sides.
--Install Circuit Werks Resonated test pipes, both sides.
--Inspect O2 sensors and replace as needed.
--Install new AOS.
--Install new spark plug/coil Oil Tubes.
--Inspect plugs and replace as needed.
--Install new Fuel Tank Pressure Sensor.
--Install new Fuel Filler door locking unit.

I have all the parts on hand. (It's nice when your garage lets you provide the parts.)


And finally, track down the short that is causing the C3 fuse (Windows/Remote Locking/Interior Lights) to blow out as soon as the fuse legs make contact in the fuse box.

Time to get this car up to speed.

After this is done, I'll be getting the seats recovered. Local shop quoted $750 for 2-tone leather, and he does very good work.

[Tweetdriver63]

Update: Circuit Werks sent the wrong pipes. What they sent was for a VW Jetta TDI. I couldn’t get hold of them quickly, so I re-ordered the pipes and had them shipped directly to the shop. Later they contacted me via email and I arranged the return of the wrong pipes.

Next issue is that one of the Davico manifolds/cats from Rockauto apparently doesn’t have a good flat joint meetup, either with the engine or the second pipe—I don’t know which—and will have to be modified. Rather than return and replace from another source, the shop will modify it. That could take 20 minutes or two hours work.

[Tweetdriver63]

Update 2:

The manifolds/cats from Davico (purchased from Rockauto) have a problem. According to the shop, they're not manufactured well and so won't seat flush with the heads. They're not an exhaust specialist shop, but very experienced with Porsches in particular, and exotics of all types. I take my Lotus to them. They have other Lotus they maintain, as well as a bunch of Ferraris, Lambos, Jags, Alfas, and a bunch of exotic classics too.

Anyway, my options are to return the Davico parts and spend a lot of money on OEM or highend aftermarket manifolds/cats, or take the car and the Davico ones to a specialist exhaust shop and see if they can work some magic to make the seal properly. I could also look for some used ones on eBay or at a recycler, but that's always iffy.

For the moment, I'm having the originals put back on so the car will be drivable. All of the other work is going to be completed as planned.

Anybody have any input? I'm not leaning toward spending the big bucks on a car that isn't worth a lot as a whole. I'll spend money (I am), but can't justify spending anything like 3 grand just on the exhaust.

[rlordjr]

Why worry about cats at all? No emissions in TN.

[Tweetdriver63]

Originally Posted by rlordjr

Why worry about cats at all? No emissions in TN.

Kind of tired of having to reset the CEL all the time. Just working on getting all my vehicles back to normal order.