noob question
 

Hey i got a simple question. im about to do this mod i have the screwable tip on my 03 boxster. Now when i drill the holes how far in deep to i drill? Do i drill al the way in ? am i supposed to make a hole in the frist chamber. How far exactly did u push the drill bit in ? Thanks for the help

Mod works on 00 non S Boxster
 

I can't see spending a grand for a new muffler,especially for the small gains it makes, but always wished the car sounded a bit more aggressive at lower rpms. Drilled two 1/2" holes, one on each side, using a 12" long bit, it made a small difference from idle-2500 rpm. Went up to a 9/16" and it sounds great now! That extra 1/16" adds over 25% more to the drilled cross sectional are, and it makes a big difference. Car sounds great at idle and normal cruising speeds, no resonace at all. Above ~3000 can't tell a difference at all, which is fine with me, it has always sounded good at higher revs. Just use a good sharp bit, push slowly and spin the drill slowly until the bit bites. The 9/16" bit fits tight on both sides as you put it in, but this helps guilde the bit and I didn't have a problem slipping. Thanks for the tip!

I did this tonight and it works great, just enough sound!!!!!

Everyone should do this mod!! i got my bit a lowes for 12.95.

Thanks for this great DIY.

Crios

That is pretty cool, I think I am going to give that a try. did you have any modifications to your air intake?
You have any other clips?

did the drills, love it, and plan on doing a second set of 1/2 inch holes strait back. Just a FYI. My drill bit was dancing all around. My tips do not come off, so the angle of attack was shallow. Some say to center punch. I used a large flat head screwdriver and pounded it into the pipe, poking a large hole, then drilled. Made the experience lasted about 2 mins per side. Obvious but someone may benifit from the suggestion.

James

I drilled two holes (one per side) also but accidentally made them a little bigger then I intended and it sounds greats. As they mentioned on here previously, more noticeable when you go past 3000 rpms and it sounds louder not different.

What are the biggest holes so far?
 

I started with 1/2"dia holes (one each side) on my 2002 2.7 and liked the extra sound. Eventually I wanted more, but could not find a larger diameter drill bit that was long enough to reach with the fixed exhaust tip. Then one day I ran across a 'stepped' drill bit and a drill bit extension, and slowly worked my way up to a 3/4"dia each side. I think it sounds even better. Definitely not too loud.

What have others tried?

I used a 1/2" drill bit but as I said earlier, I got carried away then combined with the angle, I made my holes about the same size as yours. They are 1/2" by 1" so it should be the same, I like the sound and thought about going bigger.

Does it matter if you drill almost straight back and not so much on the side? I assume you are still going into the same chamber of the muffler. I have the single tip (non-removable) and it is very hard to go at very much of an angle. Thanks.

If you drill straight back, you'll drill through the back of the muffler and you don't want to do that. Drill to side like Crios instructed. I have a 98 Boxster with a single non-removable tip and didn't have any problem. Just use a long bit, 12" or so or use a drill bit extender. You can buy both at Sears. I just increased the diameter of the holes in mine to 1". I used a step bit to increase the size. I was getting a bit of "PFFHT" sound as I rev it. The increased diameter took care of that, the sound got a little deeper and no cabin drone.

Since we got into the low 30s here in Chicagoland today, I took the Box out for a drive to see how things sounded and rid myself of some cabin fever. :dance:

Box-s Muffler drill out.
 

I was contemplating the easiest hack on my stock 00' S muffler & reading this found me with drill in hand in no time. Your'e idea is brilliant. I drilled 2 holes 7/16 in each side & with a reemer punched them out to about 11/16. Used a 2x2 chunk of fir with a 'v'groove sawn in it to guide bit. It is a perfect note w/ minimal cabin drone which goes away @ 2800. I rarely run less than that anyway. It just screams when whooped! I also recently swapped stock header/cats for chinese headers ($69.00 +32.00 ship). They are awesome for the $ & collectors/welding is just great. Extended all 02 sensors placing pre-02's near header outlet (fitting provided in hdrs) & post 02's in top of pipe right behind 2nd cats, behind rear wheel well. I am now remodelling intake. All this fancy stuff available for $3-400 is great for a neurosurgeon, but I can't see it. I got some 3.5" silicon tubing (50%+- larger than stock dia) & 2 3" abs Street 45 deg. plumbing fittings, cut them down, rasped & sanded the insides to elim drag. The stock air box provided the short section w/ MAF hub when sawn up & removed, & I'm now patterning 3/32' uhmv plastic (or whatever it's called) for a new AB to house a 4.5x5.25, 6" long Conical filter from local ap store. I opted for an oilless K&N look alike for $20.00. It will be more of a plenum than an air tube, not much sucking hopefully, the fixed dia @ MAF must be maintained to get the cfm reading though. It will throw cel's I know, but with what I've saved I'll find someone to remap ecu. Working on this car is the most fun I've ever had with mech tools. What a great car. $15K for 31K miles, are u kidding? Rich mans garbage i guess. I won/t have 18 in it for a really fun fast ride thats so addictive to drive!

Do you guys think you could do this with removed cat's?? its a 03 non-s with a remapp and intake and both cats removed... please let me know :D

I have an 03 S with a BNC filter, secondary cats removed, 200 cell primary cats, and FVD software and I love still love my exhaust mod. Go far it! It is a cheap (free) easy mod.

Ok got a drill and did it, but i only drilled one hole as its already noisey without cats..
and all i can say is WOW sounds close to a GT3, incredible gonna take it for a drive and see how she go's otherwise i recommend this mod highly!!! :cheers:

ps. il try take a video ;)

im even considering drilling a 2nd hole, but im scared about back pressure problems
iv booked the car for dyno, so ill see whats what :D hopefully there some gains :cool:

Oooh... definitely let us know the results of the dyno!

I get a BIG smile everytime I see someone do this mod! :cheers:

Ok drilled 2nd hole and reset the ECU to re-learn as my tuner said.. and WOW IT IS JUST INCREDIBLE!! dyno tomorrow morning as its a public holiday today ;)

let you know how it go's :cheers:

So who's gonna make the before and after videos?? Outside car and inside car.. :)

I'm bummed... I just did the mod on my '01 S, with 1/2" holes.. no sound difference at all! :-(

..Joe