Top Speed's Cat Back System Installation
 

The project is to replace the factory muffler, a.k.a. 'Boat Anchor', with a light, AWESOME SOUNDING Exhaust system that ROCKS!!! Cannot say enough about it…except that I am taking my car out, just to hear the SOUND!

Here's how to do it.

First, go to Top Speed in Addison on Billy Mitchell Drive and pick up one of these puppies, it comes everything you need including mounting bolts.

Tell them the North Texas Boxster Enthusiasts sent you and they will treat you like royalty with a TS baseball hat and license plate frame FREE (maybe a discount too)! Of course, for you Honorary Members, you can order it online…

The system works best with Cat Bypass pipes or 'test pipes' (unless you are in CA-sorry see your state regulator about that). Even better IF you have an Air Intake too!

Here's what it looks like out of the box…
http://986forum.com/forums/uploads01...1355230357.jpg

This is all most people see of the muffler…pity to hide all that beautiful work.
http://986forum.com/forums/uploads01...1355230591.jpg

It is actually harder to get RID of the factory unit than to put in the TS Cat Back system! So, most of this DIY covers un-doing the muffler.

Here is a pic of the stock scrap BEFORE removing...
http://986forum.com/forums/uploads01...1355230714.jpg

To preserve your knuckles get a 15mm deep socket (13mm wouldn't hurt either) and a swivel socket if you do not already have one. Past that, you use open end wrenches and elbow grease.
http://986forum.com/forums/uploads01...1355230819.jpg

Undo these bolts, they are 13mm, don't worry, it will not fall on your head...
http://986forum.com/forums/uploads01...1355230924.jpg

These bolts are also 13mm connecting the bypass pipes or 2ndary Cat pipes to the "U-Bend". They will be tight! Use some PB Blaster and let it soak in to make your life easier.
http://986forum.com/forums/uploads01...1355230996.jpg

Next is the 15mm bolt connecting the muff to the exhaust pipes. Loosen and remove. Not the muff, but the pipes connecting it.
http://986forum.com/forums/uploads01...1355231144.jpg

If you have Cat Bypass pipes, they will have a 12mm that is easily loosened, remove the Bypass adapter piece they are connected to.
http://986forum.com/forums/uploads01...1355231220.jpg

…as seen here. Do this for BOTH sides. Remove the U-pipes too.
http://986forum.com/forums/uploads01...1355231325.jpg

This is where it gets fun. The pic is hard to see but there are two 13mm bolts here that you have to remove….

CAUTION: Loosen one of the bolts and DO NOT remove until you are ready to remove them both AND TRY TO GET OUT OF THE WAY when she falls!

So, get them backed out about halfway and then do the other side. You DO NOT want this Boat Anchor falling on your HEAD!

It is HEAVY (ever wonder why the new exhaust works so well - it is half the weight - but that's just HALF the reason…the SOUND is what will make you smitten).
http://986forum.com/forums/uploads01...1355231437.jpg

(to be continued)

O.K. so you got the old junker off there. It should look like this before you throw it out…
http://986forum.com/forums/uploads01...1355232465.jpg

Another view of me kicking it to the curb! NOT RECOMMENDED as it will hurt your foot!
http://986forum.com/forums/uploads01...1355232531.jpg

The new shinny, young muff will go in easily where the old one used to be. For the Box we will use the long bolts, and lock nuts and washers that came with the kit. Not much explanation needed here.
http://986forum.com/forums/uploads01...1355232601.jpg

"Dry-fit" the U Pipes in with the banded bolts that came off the car. Easy.
http://986forum.com/forums/uploads01...1355232718.jpg

Connect the U Pipes to the Bypass pipes, test pipes or factory pipes on both sides…simple, huh?
http://986forum.com/forums/uploads01...1355232809.jpg

Here's a tip to get them separated enough to get some 'wiggle room' to fit them in the right place...
http://986forum.com/forums/uploads01...1355232930.jpg

Here is what it looks like on there dry-fitted...
http://986forum.com/forums/uploads01...1355233006.jpg

All on? Then, tighten them ALL DOWN tight. You may need to re-check tightness in a couple hundred miles…just to be sure.
http://986forum.com/forums/uploads01...1355233088.jpg

Now do the other side….almost there! Cannot wait to hear it! That took all of a few minutes to do. You are almost there!
http://986forum.com/forums/uploads01...1355233182.jpg

Drop it off the lift, not literally, and get ready for some fun!
http://986forum.com/forums/uploads01...1355233291.jpg

Please note that it will take a couple hundred miles or so for the "carbon to develop the full sound AND power of this exhaust". So put on BEFORE you go out for your track day.

One other note is your gas mileage will suffer FROM YOU PLANTING YOUR FOOT ON THE FLOOR TO HEAR THE ROAR!!! Enjoy!

See Ya!

Since I started promoting the Charlie Chan Muffler, I think the Gross National Product of China has gone up 6%. They oughta love me long time !

Is there any highway cruising drone with this system at between 2-3k rpm? I really would like to get a lighter system but I do enjoy the stock sound when you jump on it and how it is very quiet cruising on a long trip

Hi @oc-boxster,

Nope. No drone! Since i use my car for work too, I was worried about that. Did not find ANY drone at all! In fact, you will not stay in that section of the RPMs since the exhaust note is such beautiful MUSIC! You will find yourself stepping on it to hear the symphony out back! REALLY pleased with my setup now!

@JD,
I thought you were getting all the love you could handle? You're right tho, IF there was only a way to get a PIECE of the action!

Thanks! I'm pretty sure I will get one now

i just checked the Bloomberg website.
the exact number is 6.2 % :D

Danger makes Charlie Chan muffler "Swing American" !!!!!

Muffler brand?
 

found a picture of this exact muffler online at FRSPORTS.com,

only $299(onsale for $269 with axle back pipes too, is it the same muffler?
seems like its too good of a price to be real- must be from china?

^ I don't see any Porsche parts on that site?

That's the Hunan version.

HECK YES THERE IS DRONE AND CABIN RESONANCE at 2-3k rpm. You'll be upshifting to get away from it in town. Top down its not bad, but top up its deafening to me.

Of course, I have the larger Che headers and this may make mine louder than other guys with stock headers...

Thanks for the info-I've had exhaust systems installed on previous vehicles and I just can't take the drone anymore-maybe I'm just getting old.

No Headers for me…yet. But, no drone either! I accelerate well past the 2-3k rpm range just to hear it but if I am listening to music, I have a hard time telling I have upgraded the exhaust. Press the pedal to be sure, and it's there sounding fine as the music fades to the background. NICE!

I have a before and after video IF I could figure out how/where to post it. Guess there's always MeTube.

I finally got around to working on my exhaust again last week. I had a little bit of drone but suspected it was where the bypass pipes connected with the chintzy clamp that was included. I had a little bit of a leak no matter how hard I tightened the clamps. I looked around for a sealing exhaust clamp in a 2" size. I found some at Pep Boys but they didn't have 2" so I found them on line at another supplier. I installed them and now, no drone! They are very nice clamps securing the pipes and adding a little more metal which probably helps with any drone while also sealing the joint. The bypass pipes/exhaust combination definitely increases the torque and response. I have gotten wheel spin several times now and the car feels more alive. Here's some pictures of the clamps:

http://986forum.com/forums/uploads01...1358874335.jpg

http://986forum.com/forums/uploads01...1358874376.jpg

http://986forum.com/forums/uploads01...1358874430.jpg

http://986forum.com/forums/uploads01...1358874454.jpg

nice job Bruce.
mind posting the link for the clamp?
just want to be sure i'm ordering the correct size.
thanks.
Meir.

No problem Meir. Here is the link, I got the 2" size, with shipping it came to $27.30.

EasySeal Exhaust Clamps: Torca EasySeal Clamps in Stainless Steel for Lap Joint Connections

Pep Boys carries the clamp but none of them carried the 2" size in my area. I tried Autozone and a couple other auto parts stores but no one carried these. I really like them because they make a nice seal. As you tighten it, the band forms to pipes.

Thanks Bruce….got mine ordered! I too have had similar problem. This was an easy fix.

Thanks!
Mark

Nice pics guys.
Remember when you could hear the intake?
All I can hear now is the exhaust.

Yep, the sound of the intake is definitely no longer heard!

Got a compliment at the stoplight the other day from a guy in a white 3 series. Said my exhaust was amazing. :cool:

thanks Bruce.
ordered the clamps.
looks like all of us has issues with the TS pipes.

Yep, the included clamp just doesnt cut it IMO.

I just took the plunge as well but being in CA I can't delete the CAT's, however I have heard that at least one person in CA removed the 2ndary CAT's and it still passes CA smog tests.

Anyone else in CA remove the 2nd CAT's?

Got the System today from UPS at 1:30pm, (3 days from order) started the install at 2pm, finally had the old muffler out at 3pm and got all the new stuff installed, cleaned up the tools and took the car off the jacks by 4pm.

Its pretty easy using liberal amounts of WD40 so all the clamps slide easy and nuts come off without much trouble.

I did waste about 15 minutes trying to put the U pipe between the muffler and 2ndary CAT back in place backwards and wondered why it would not fit....duh!

Once I got that sorted out everything went together quickly.

Its an easy DIY and I did shim the muffler back towards the rear about 1/2" so the nice tips stuck out a bit more.

I did the before and after exhaust video and the shim pic which I'l post this weekend.

No instructions to add to this thread as it has everything well covered.

It may pass the sniffer, but it won't pass visual! It's OK though. Most of them don't know what they are looking for.

I will say this: if your put shiny exhaust parts on the car? It will catch their attention!!

I hotrod the street cars with factory 996 exhaust pieces so it all looks normal under the car. I like to use 3.6L cats under the cars with the part numbers facing down, so again, it looks normal.

I doubt the shop ihave been going to has ever seen a boxster.

My Wrangler with cracked headers passes there with flying colors.;)

Their usual clientel drive those minature red pickups with lawnmowers and ladders on the back.

My morning commute was awesome this morning listening to my new exhaust.
Radio muted as the sound is too nice not to listen too while going through the gears.

The exhaust note has definately changed to a throatier, full bodied, but not overly load roar. Strangely sounding Lion like if that makes any sense.

It really sounds like I imagined a racy sports car should sound. With all 4 cats still in place the volume has not increased much which is also nice since its not obnoxious.

I also noticed the faster throttle response and found myself reaching shift points a bit quicker.

This is just the first day driving it and I'm quite pleased with my $320 investment.

Apparently the muffler needs to break in, and so the tone will continue to improve for the next ~100 miles I've heard.

Big Thumbs up on this easy DIY and modestly priced upgrade. :D

Thanks for the update!

Have you noticed any of the fiberglass spewing issues people have reported?

I had the fiberglass for a few months but it has stopped.

I did notice a bit of whitish dust on the lower part of the bumper.

I suppose thats the fiberglass dust.

Glass being harder than paint, you dont want to rub that off but rather wash it off so that you dont put micro scratches on your paint and dull the finish, or get glass particles embeded in your skin.

I also noticed a bit of a drone between 2000-3000 rpm yesterday but it is much less today so perhaps its temporarily part of the muffler break in.

Here are a few pics:

Here is what I got for $320. Muffler, 4 bolts/nuts/washers, stickers and lic plate frame. Porsche 986 Boxster 2 5L 2 7L Boxster s 3 2L 97 04 Performance Exhaust System | eBay
https://lh4.googleusercontent.com/-d.../CIMG3541a.JPG

Adjustment spacers at the attach bracket to get the tips to stick out a bit farther.
https://lh5.googleusercontent.com/-Z.../CIMG3544a.JPG

Need to adjust pipes alignment slightly
https://lh6.googleusercontent.com/-q.../CIMG3546a.JPG

I think I need to pull the trigger on this, great idea for the new exhaust clamp, it looks very clean!

That looks really good. Where did you buy it from? and did you install the cat bypass pipes as well (as in BruceH's pictures at the bottom of the thread).

This is the same exhaust that is all over eBay UK and typically buy it now £299. On boxa.net you will also find a load of owners who have this with/out the manifolds.

I did! Secondary cat eliminator pipes, Fister/ Pedro mod. and I passed
smog in San Diego. Well below limits.

Was it still quite enough without the 2nd cats or does the sound level go up significantly?

I added the link to the picture post:
Porsche 986 Boxster 2 5L 2 7L Boxster s 3 2L 97 04 Performance Exhaust System | eBay

Make sure you are getting it from the Top Speed company from Addison, Texas so you don't get one of the potentially ill fitting, inferior china copy-cat products.

I did not install the pipes but there is another thread on this forum for the pipes if you search for "Top Speed Pipes"

There is also the Pedro's Sport Exhaust option.
http://www.pedrosgarage.com/Site_3/Make_the_Pedro_Sport_Exhaust.html

Update.

After having this exhaust for 2 weeks the fiberglass particles have stopped and the muffler sounds good except for a drone between 2500 -3000 rpm.

So to complete the job and get rid of the drone I just ordered the 2nd cat bypass from Top Speed as well for $199.

Hopefully that gets the sound right, and will shed another 25 lbs by deleting the 2nd cats.

Pics and description coming soon

Did you get the clamps that I linked to earlier in he the thread? The clamps that come with the kit do not seal the joint, the clamps I bought take care of that air leak which helped a lot with my drone. I also have the cat bypass pipes.