DIY Exhaust Mod – Gain of 10+ HP!!!

[jesseborgelt]

Originally Posted by Spinnaker

2000 S with welded tips, see post #128. Didn't have much trouble at all.

"Have peeps found that duct tape is the best way to prevent any scratching?... "
The smooth surface of the extension did not leave any discernable marks on edge of the stainless steel tips.

I made a few attempts at this and walked away frustrated more than once. When I finally got it to work out the way I wanted it to, I was happy with the results. I had very realistic expectations for simply punching holes in a muffler and I like the sound better then stock.
My tips:
1) Take a shop rag fold it in half and line the inside of the tip with it while draping the excess over the outside of the tip and tape into place, both outside and inside. I used blue painters tape.
2) I got a cheap set of ridiculously long bits (like 30”) from Harbor Tool and Freight for under $15 for a set of 4. Using the smallest bit, I attempted to drill a hole which spun along the curve of the inside of the exhaust pipe to no avail. I peered into the pipe to see where I wanted the hole to be with the drill bit, then while maintaining my vision on the spot, removed the drill and replaced it with a long screwdriver. Bang the hell out of it because you must have a dent or small hole for the bit to catch on, otherwise you will get frustrated and the bit will spin everywhere.
3) With the hole punched, I set the bit in the hole and stepped up the sizes until I had a 3/4” hole carved out. I really had to put some effort into it, as I believe these are wood bits, but for $15 I don’t care about messing them up.
With the desnorkle accomplished at the same time, I felt like have done something good for the car.

[hartids]

Desnork and exhaust mod both achieved in under half an hour!! So so so worth it!! I really believe that the sound difference is instantly noticable... Not crazy loud but a definate deeper growl and at about 3200rpm through the lower gears it really buzzes nicely!! The only trouble I had while attempting both mods was getting the air intake off for the desnork... That thing really needed some brute force!! As soon as it was off no problems at all, hardly even had to pull the snorkel and it popped straight out!!

As for the exhaust mod I got a 12" hardened tip flat head and gave it a good few whacks right where I wanted the drill bit to take. Made a nice big dent which my 1/2" metal drillbit (12" long) grabbed hold of and went straight through with some heavy force. I went to do the same thing on the left pipe - gave the screwdriver a few whacks and actually punched straight through with the driver making about a 1/2" hole to match the first one!! Result - Didn't even need to get the drill out!!

The sound difference is clearly noticeable on my '98 2.5 man so I imagine it will sound really nice on the 3.2 S models with both mods. I'll upload a pic of where I punched the holes...

On another note has anyone ever considered tinting the rear plastic window? Mine is quite badly damaged and cloudy, can't really see a whole lot through it - tried a load of different specialist cleaning products but to no avail!! I know you can get pre-cut tint film for them but this is applied on the inside and I don't think it will cover up the damage.. I have some spray on tint but not sure if it will stick to the plastic? I'm up for giving anything a go to make it better as I can get a new window fitted for £195 if nothing works.

Any ideas?

Cheers all,
Hartids

[Idaho Red Rocket 3]

My window tint guy said it could be done but he would not guarantee it would stay on when the top is folded down. So I had him tint the wind-stop. Works great because whether the top is up or down, I always have a tinted rear window.

[hartids]

Thanks IRR3, that is definately an option for a tinted look at the back but it won't cover up the damage on my window which is what I am trying to achieve. I think i'm going to have to just put my hand in my pocket and pay out for a replacement window. I'd be up for giving anything else a go before I get the new one fitted if anyone has any ideas? I've tried cleaning and cleaning with specialist plastic window restorer which has worked on the clear sections but the cloudy patches just won't come out. Is there something more industrial I can try (maybe electric buffing) or any other way of staining or tinting the window to cover it up? I do have some headlight smoked tint spray which I am going to use on my front indicators (amber sections) but I think this will just come off with all the movement in the roof if I use it on the rear window. On that subject does anyone know if I need to sand the lights before applying the spray? The directions on the can say that they just need to be cleaned and oil free but I think maybe the spray will take better on a roughened surface?

Cheers all,
Hartids