Go Back   986 Forum - for Porsche Boxster Owners and Others > Porsche Boxsters > DIY Project Guides

Reply
 
LinkBack Thread Tools Display Modes
Old 03-02-2009, 11:41 AM   #1
Registered User
 
Join Date: Dec 2008
Location: Fresno
Posts: 163
DIY Exhaust Mod – Gain of 10+ HP!!!

DIY Exhaust Mod – Gain of 10+ HP!!!
10+, I wish, LOL, but it sure does sound better

I’ve thought about doing the PSE mod for a while now, but after doing some research I thought there was a cheaper and easier way, so I tried it.

My theory is this. The inside of a 986 muffler has the exhaust going from chamber to chamber before exiting, what if I could decrease the amount of chambers?

See image below, the RED is the where the exhaust comes in, and then it goes to AQUA, before existing via the TAN.
My mod is allow fumes to exit much faster by opening the exit pipes to the first chamber, see the GREEN line.

Below are directions what I did. Let me know your thoughts:

Take the Tips off:

Tool needed, I used a ½ inch drill bit:

Now drill away:

Both sides should be drilled into and then would look like this:

2nd Pic

Install Tips back on, after cleaning of course…and enjoy the new throaty sound without the deafening/annoying drone!!

I guess one could try larger drill bits and it would get louder, but I’m sure there’s a point before the drone comes into play.
I don’t have a sound file of the before, but here is the after for your hearing pleasure:
http://www.youtube.com/watch?v=RfRErzkyqNc

Thanks,
Cesar
__________________
-Cesar

03' 986 Midnight Blue Metallic
_____________________________________________
Gemballa Lowering Springs | 18” Carrera Light Wheels | Painted Calipers
14/18 H&R Spacers | Aero Wing & Rockers | Powder Coated Exhaust
Creator of CRIOS exhaust mod | De-Snorkeled | De-Ambered
Light Weight Flywheel | Tinted Windows and Windscreen
Painted Bumperettes | 550 Spyder Grille Kit


http://lh5.ggpht.com/_9sTq_sN1KDw/Si...2009%20055.jpg
crios is offline   Reply With Quote
Old 03-02-2009, 05:10 PM   #2
Registered User
 
Join Date: May 2007
Location: SoCal
Posts: 188
I have done PSE mod on mine, maybe i should try to do this as well to compliment PSE and if it doesnt work i could weld it back up
blueillusion97 is offline   Reply With Quote
Old 03-02-2009, 05:44 PM   #3
Registered User
 
Join Date: Jul 2004
Location: Houston, Texas
Posts: 6,654
Now this is a great little mod. Probably took all of a half hour, right?

I cannot tell from the video just how much louder it is, but it does sound "throatier."

Give us your opinion as to how much better it sounds. Do you still long for a different muffler that's louder if you could get one without the nasty cabin drone?
__________________
'97 Boxster (Black Hole for Dead Presidents) - 115k
Quite possibly the most repaired Boxster on the road...
mods/repairs/pix: www.iwantaporsche.net
RandallNeighbour is offline   Reply With Quote
Old 03-02-2009, 07:02 PM   #4
Registered User
 
Join Date: Dec 2008
Location: Fresno
Posts: 163
30 min if that!! I'm wanting to drill wider to make it louder, but scared there might be drone past 1/2 inch. I'll post some more clips tomorrow on how loud it is, but I'd say it probably increased it by 10-20% at the most. Not as loud as PSE for sure, but better than stock.


Quote:
Originally Posted by RandallNeighbour
Now this is a great little mod. Probably took all of a half hour, right?

I cannot tell from the video just how much louder it is, but it does sound "throatier."

Give us your opinion as to how much better it sounds. Do you still long for a different muffler that's louder if you could get one without the nasty cabin drone?
__________________
-Cesar

03' 986 Midnight Blue Metallic
_____________________________________________
Gemballa Lowering Springs | 18” Carrera Light Wheels | Painted Calipers
14/18 H&R Spacers | Aero Wing & Rockers | Powder Coated Exhaust
Creator of CRIOS exhaust mod | De-Snorkeled | De-Ambered
Light Weight Flywheel | Tinted Windows and Windscreen
Painted Bumperettes | 550 Spyder Grille Kit


http://lh5.ggpht.com/_9sTq_sN1KDw/Si...2009%20055.jpg
crios is offline   Reply With Quote
Old 03-02-2009, 07:40 PM   #5
Registered User
 
Join Date: May 2006
Location: Toronto
Posts: 277
Quote:
Originally Posted by crios
I'll post some more clips tomorrow
wanna986 is offline   Reply With Quote
Old 03-03-2009, 10:08 AM   #6
Registered User
 
Join Date: Dec 2008
Location: Fresno
Posts: 163
Hi all,
Below are some more clips I put together this mornig. I'd say the increase sound is anywhere from 10-20%, not huge, but then again, I only used a 1/2 drill bit. You hear the throaty sound more in the lower RPMs.

Boxster Exhaust Mod - Outside #1
http://www.youtube.com/watch?v=Dt0p0etZt7s

Boxster Exhaust Mod - Outside #2
http://www.youtube.com/watch?v=3uQYZj2xUfE

Boxster Exhaust Mod - Topdown
http://www.youtube.com/watch?v=EDGR78lMLF8

Boxster Exhaust Mod - Top Up
http://www.youtube.com/watch?v=GOumu9oH1pU

Thanks,
Cesar
__________________
-Cesar

03' 986 Midnight Blue Metallic
_____________________________________________
Gemballa Lowering Springs | 18” Carrera Light Wheels | Painted Calipers
14/18 H&R Spacers | Aero Wing & Rockers | Powder Coated Exhaust
Creator of CRIOS exhaust mod | De-Snorkeled | De-Ambered
Light Weight Flywheel | Tinted Windows and Windscreen
Painted Bumperettes | 550 Spyder Grille Kit


http://lh5.ggpht.com/_9sTq_sN1KDw/Si...2009%20055.jpg

Last edited by crios; 03-03-2009 at 03:14 PM.
crios is offline   Reply With Quote
Old 03-03-2009, 10:45 AM   #7
Registered User
 
Join Date: Aug 2005
Location: Sanford NC
Posts: 1,362
How did you prove it added HP?

And at what RPMs?

Butt dyno doesn't count, BTW.

signed
the resident skeptic
mikefocke is offline   Reply With Quote
Old 03-03-2009, 11:00 AM   #8
Registered User
 
Join Date: Dec 2008
Location: Fresno
Posts: 163
Mike,
I promise not to rev it by your house...lol

It's not that loud, it's 1/2 in hole on each side, perhaps an 1 inch whole would be better, but what if then there is drone in the cabin at crusing speeds, which I've heard first hand and hated.

As for the RPM ranged...you saw the distance I drove to and back, but I would guess between 3-5K. Standing still ones probably went as high as 7K.

This is meant to be a inexpensive hack, I'm not about to fork out $$ for a dyno to prove skeptics. If you are skeptic, don't do it. I'm not selling anyone anything, I have no agenda, other than having fun with my Boxster and sharing the experience with others.

Thanks,
Cesar


Quote:
Originally Posted by mikefocke
And at what RPMs?

Butt dyno doesn't count, BTW.

signed
the resident skeptic
__________________
-Cesar

03' 986 Midnight Blue Metallic
_____________________________________________
Gemballa Lowering Springs | 18” Carrera Light Wheels | Painted Calipers
14/18 H&R Spacers | Aero Wing & Rockers | Powder Coated Exhaust
Creator of CRIOS exhaust mod | De-Snorkeled | De-Ambered
Light Weight Flywheel | Tinted Windows and Windscreen
Painted Bumperettes | 550 Spyder Grille Kit


http://lh5.ggpht.com/_9sTq_sN1KDw/Si...2009%20055.jpg
crios is offline   Reply With Quote
Old 03-03-2009, 11:58 AM   #9
Registered User
 
Join Date: Sep 2006
Location: new jersey
Posts: 404
******************** i like this idea.. now for my question i have the oval shaped exhaust tip.. does that just come right off ? like is it held on with a screw.. as i have not been underneath the car to know and it is also 12 degrees out with snow on the ground so not sure i am going to venture going under the car right now...
clb0099 is offline   Reply With Quote
Old 03-03-2009, 12:25 PM   #10
Schatten-Baum-Mechaniker
 
Join Date: Mar 2005
Location: Mississippi
Posts: 229
I think this exhaust tip configuration varies by year. Beside the obvious single vs. dual. Mine is a 2000 S, the inner tip extensions appear to be welded to the muffler and the outer polished tip is screwed in AND tack welded. So to do this mod i need a really long drill bit and it would also be hard to get the correct angle to drill into the side.
__________________
Tommy
2000 Boxster S
1973 914
tommy986 is offline   Reply With Quote
Old 03-03-2009, 01:36 PM   #11
Registered User
 
Join Date: Dec 2008
Location: Fresno
Posts: 163
That's correct. I think the tips were removable starting in 02, so anything prior is welded on and you'll need an extra long drill bit.

All mufflers still had the two pipes exiting, so two holes on each side will still need to be completed.
__________________
-Cesar

03' 986 Midnight Blue Metallic
_____________________________________________
Gemballa Lowering Springs | 18” Carrera Light Wheels | Painted Calipers
14/18 H&R Spacers | Aero Wing & Rockers | Powder Coated Exhaust
Creator of CRIOS exhaust mod | De-Snorkeled | De-Ambered
Light Weight Flywheel | Tinted Windows and Windscreen
Painted Bumperettes | 550 Spyder Grille Kit


http://lh5.ggpht.com/_9sTq_sN1KDw/Si...2009%20055.jpg
crios is offline   Reply With Quote
Old 03-03-2009, 03:23 PM   #12
Registered User
 
Join Date: Mar 2008
Location: CA
Posts: 726
we need to get someone with a 2.7 who has the "pedro" mod to do some side by side sound comparisons..

I wonder how much louder the pedro mod would be.... your mod seems to be almost the same thing... instead of adding plumbing to the outside - to route exhaust gas around the outside of the muffler, you are instead, letting it just bypass many of the internal chambers - and get out much faster - which is essentially the same thing....

i have a 2.7 2000 - and from listening to your youtube clips - the sound is a LOT different than just bone stock. it sounds louder and throatier. I like it! and it's FREE!!!! i wonder if you can "undo" it if you got sick of it???

what you need to do is find a way to put a "plug" or a bung on that hole - so when you take the wifey with you - you can just "plug" it...and make it sound like stock.. kinda like a cheapo bypass valve... open it for most of the time, and if/when you need to be super quiet...you plug it up.

i wish you lived closer to me, I want to hear it.

hey, in that video when you rolled by i got a nice shot of your yellow calipers. I like 'em!
23109VC is offline   Reply With Quote
Old 03-03-2009, 04:24 PM   #13
Registered User
 
Join Date: Sep 2006
Location: new jersey
Posts: 404
So i have to get the tip removed and drill the holes ..then have the tip welded back ..Or is the any way i can do the holes without removing the tip?
clb0099 is offline   Reply With Quote
Old 03-03-2009, 07:04 PM   #14
Registered User
 
Join Date: Oct 2008
Location: San Diego
Posts: 434
Started this last night, finished up this evening on my '03 non-S boxster.

The oval tip comes off by removing one 13mm bolt.

I used a 7/8" tapered bit, so the holes I wound up with are quite large - 7/8" by about 1.25 or 1.5" because of the angle at which I drilled.

I have not had a chance to open the throttle up properly - rolling on my spare right now, as I picked up a nail on the way to work today - but once I get a proper tire on, we'll see how it sounds. It currently reminds me of the Injen catback I had on my Tiburon, which I loved dearly.

The best part about this 'mod': if you hate it, pick up a used Boxster muffler for $50.
sd_boxster is offline   Reply With Quote
Old 03-03-2009, 07:38 PM   #15
Registered User
 
Join Date: May 2006
Location: Toronto
Posts: 277
Quote:
Originally Posted by crios
but what if then there is drone in the cabin at crusing speeds, which I've heard first hand and hated.
So, no drone with the 1/2" holes?
Really, though, this mod is quite easily reversed.
Thanks for posting the clips.
wanna986 is offline   Reply With Quote
Old 03-03-2009, 07:39 PM   #16
Registered User
 
Join Date: Sep 2006
Location: new jersey
Posts: 404
are you sure that is true about the oval tip as my car is a '97 and i am getting from alot of people that it is welded on and not screwed on.. and i have looked at pictures of mufflers from different yrs and some have the bolt and some looked welded on
clb0099 is offline   Reply With Quote
Old 03-03-2009, 07:48 PM   #17
Registered User
 
Join Date: Dec 2008
Location: Fresno
Posts: 163
Yours are welded on, you need to buy a long drill bit, but you should be able to do without taking anything off.

http://beta.sears.com/shc/s/p_10153_12605_00966164000P?vName=Tools&keyword=1/2+Drill+Bit


Quote:
Originally Posted by clb0099
are you sure that is true about the oval tip as my car is a '97 and i am getting from alot of people that it is welded on and not screwed on.. and i have looked at pictures of mufflers from different yrs and some have the bolt and some looked welded on
__________________
-Cesar

03' 986 Midnight Blue Metallic
_____________________________________________
Gemballa Lowering Springs | 18” Carrera Light Wheels | Painted Calipers
14/18 H&R Spacers | Aero Wing & Rockers | Powder Coated Exhaust
Creator of CRIOS exhaust mod | De-Snorkeled | De-Ambered
Light Weight Flywheel | Tinted Windows and Windscreen
Painted Bumperettes | 550 Spyder Grille Kit


http://lh5.ggpht.com/_9sTq_sN1KDw/Si...2009%20055.jpg
crios is offline   Reply With Quote
Old 03-03-2009, 07:49 PM   #18
Registered User
 
Join Date: Dec 2008
Location: Fresno
Posts: 163
None at 1/2 inch, don't know if 1 inch would have....waiting to see if other attempt and what they think before going bigger, but I do want to go bigger!!!

Quote:
Originally Posted by wanna986
So, no drone with the 1/2" holes?
Really, though, this mod is quite easily reversed.
Thanks for posting the clips.
__________________
-Cesar

03' 986 Midnight Blue Metallic
_____________________________________________
Gemballa Lowering Springs | 18” Carrera Light Wheels | Painted Calipers
14/18 H&R Spacers | Aero Wing & Rockers | Powder Coated Exhaust
Creator of CRIOS exhaust mod | De-Snorkeled | De-Ambered
Light Weight Flywheel | Tinted Windows and Windscreen
Painted Bumperettes | 550 Spyder Grille Kit


http://lh5.ggpht.com/_9sTq_sN1KDw/Si...2009%20055.jpg

Last edited by crios; 03-03-2009 at 07:54 PM.
crios is offline   Reply With Quote
Old 03-03-2009, 07:58 PM   #19
Registered User
 
Join Date: Dec 2008
Location: Fresno
Posts: 163
1.5 inches, wow! You have to post some clips!!!! How does it sound just reving it in park?





Quote:
Originally Posted by sd_boxster
Started this last night, finished up this evening on my '03 non-S boxster.

The oval tip comes off by removing one 13mm bolt.

I used a 7/8" tapered bit, so the holes I wound up with are quite large - 7/8" by about 1.25 or 1.5" because of the angle at which I drilled.

I have not had a chance to open the throttle up properly - rolling on my spare right now, as I picked up a nail on the way to work today - but once I get a proper tire on, we'll see how it sounds. It currently reminds me of the Injen catback I had on my Tiburon, which I loved dearly.

The best part about this 'mod': if you hate it, pick up a used Boxster muffler for $50.
__________________
-Cesar

03' 986 Midnight Blue Metallic
_____________________________________________
Gemballa Lowering Springs | 18” Carrera Light Wheels | Painted Calipers
14/18 H&R Spacers | Aero Wing & Rockers | Powder Coated Exhaust
Creator of CRIOS exhaust mod | De-Snorkeled | De-Ambered
Light Weight Flywheel | Tinted Windows and Windscreen
Painted Bumperettes | 550 Spyder Grille Kit


http://lh5.ggpht.com/_9sTq_sN1KDw/Si...2009%20055.jpg
crios is offline   Reply With Quote
Old 03-04-2009, 10:02 PM   #20
Registered User
 
Join Date: Oct 2008
Location: San Diego
Posts: 434
Video clip, as requested.

There is definitely a difference. My tires are once again holding air, so I went for a drive. There is some resonance at ~2900RPM, but it is not 'drone', and it's only noticeable for a range of about 100 RPM either side of 2900. Most noticeable difference is at low RPM - just sounds a little meaner.

I like it. I paid $600 or so for an Injen exhaust that didn't sound appreciably better than this.

The drill bit cost me less than 30 bucks. Not bad, considering how many people I've seen drop a thousand dollars on an exhaust they wound up hating.
sd_boxster is offline   Reply With Quote
Reply


Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On



All times are GMT -8. The time now is 03:13 AM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2014, vBulletin Solutions, Inc.
Content Relevant URLs by vBSEO 3.6.0
Copyright 2011 Pelican Parts - Posts may be archived for display on the Pelican Parts Website -    DMCA Registered Agent Contact Page