Boxster S 2001 sport exhaust question
 

Hello

Just wondering if anyone can help. I've been told my exhaust back box is split, may fail upcoming mot and need replaced. If it does fail I want to get the same exhaust again (I think - unless anyone has better idea for me). I believe I've got the sport exhaust with the supersound tailpipe. Hopefully see attached photos.

My garage told me that the sport exhaust comes as one part (sorry I'm not technical) but to me looking at parts online it looks like the supersound muffler/pipes is an add-on? I'm just wondering if someone can help by explaining what the official product part number is for my exhaust? Does it come as one part or is it separate parts and does it require any welding when fitting it all?

Thank you http://986forum.com/forums/uploads02...1484607956.jpg


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Why can't they fix/weld the split? You have a factory Porsche Sports Exhaust which is very expensive (about $3200 from Porsche right now). It is one piece, and you cannot buy the tips separately. The "super sound tips" you are referring to work with the Dansk sports exhausts that can be bolted onto the Dansk exhaust without the tips (made to accept varied tip designs), or one that is pre-welded on the Dansk (as I have on my car below). They are not made to work with your factory PSE, but maybe a welder can help you to adapt it somehow. Here's what the tips themselves look like (as you can see, they are not made to accept the two pipes coming in from the sides): http://m.ebay.com/itm/Dansk-Sport-Exhaust-Tips-Super-Sound-Look-For-Boxster-Porsche-reg-/182089606084

Alternatively, if you like the look of those tips, you can buy what I have and have it installed...it will have a similar look, but without the long pipes feeding the tips. Designtek also rebrands the Dansk exhaust, and sells it closer to where you are located: https://www.designtek.eu/DesignTek-Exhaust-Muffler---Silencer--SUPER-SOUND--Porsche-Boxster-986/prod17330/

Something else that MIGHT work (although I'm not sure of it cause I never tried it) is for you to buy a used 2003/04 factory exhaust (which allows for tips to be bolted on), and then you buy the dansk super sound tips (tips only), and try to bolt them on the factory 03/04 muffler. That could be your cheapest option if it works. Good luck.

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I agree with Boxtaboy... get it fixed.

I have the same exhaust. It is a Porsche Sports Exhaust or PSE; part number is 99611198700. It is somewhat rare and IMHO very special looking. The muffler is petty easy to remove and if you have a problem it should be fairly easy to have it repaired. It is sold as a unit and there are no parts available for it.

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Thanks guys. Yeah to be honest I don't want to get rid of it either. Like the look and the sound.

We spoke about 6 months ago (garage and I) so from memory can't remember exactly what he said but I'm sure he said something like it has split from the inside so can't be mended? Would that make sense?

If it does need to be replaced, what is the best alternative for performance and sound? Not wanting to spend an absolute fortune either as just replaced the clutch,flywheel and ims bearing last year.

Other than the options I gave you above, if you don't care about the look of the supersound tips, just get a used stock muffler and ask a muffler shop to weld in bypass pipes for extra sound. That's the cheapest option.

Can you hear any problem inside your current exhaust? Is there a leak or internal broken chamber? Not sure what could be the problem by just your description, but it's rare that these mufflers crack internally.

Find a muffler shop and deal with them. IMHO, it will be much cheaper to repair this one than replace it. They can be cut open too for any internal repair. I have never heard of a Boxster muffler having an internal failure. And get some polish on that thing. ;)

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Cheers guys.

Boxtaboy - don't think there is any issues with the exhaust. Don't hear or feel anything wrong. It's going in for mot on 6th Feb so will get the garage to explain more about the split then. Sometimes they aren't too clear when explaining issues. Thanks for trying to explain alternative options too.

Chuck - thanks for your input too. Will investigate if there are any muffler specialists around Edinburgh just incase I can get it repaired if needed, as first option. Also appreciate the picture of what it looks like brand new....now I realise the backbox should not be the dirty grimy colour it is.will get some Polish to it soon. I hope it can scrub up well again as will look cool all polished up.

Chuck - Any suggestions for a polish that would bring it all back up looking gleaming again?

Cheers

Below is a before and after photo of my exhaust. These exhaust are stainless steel and with some effort will shine. I first used a 2" 320 grit Scotch Brite Polishing Ball on a power drill along with Blue Magic Metal Polish Cream.Any metal polish will work, I just had the Blue Magic on the shelf. It was good stuff for taking the top layer of grit. I then used brake cleaner, Mothers Mag & Aluminum Polish and applied this by hand using 0000 super fine steel wool. This cleaned it up more and added some shine. Lastly, I put several coat of Mothers Mag & Aluminum Polish on by hand rubbing it in well then buffing it with a soft cloth. I would guess I put 10 to 12 hours into the polishing of it.

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Superb job!

Thanks... let us know the outcome on yours. I am curious where the issue is.

Hi guys, so failed the mot on emmissions. As i said before, been told the exhaust needs replaced. Chuck - i cant seem to find a specialist exhaust/muffler repairer in Edinburgh, Scotland, for an opinion on whether it can be repaired. My independent specialist I take the car to doesn't believe it can be repaired.
Boxta boy - what's the sound like from your Dansk exhaust with ''super sound'' tips?? This seems to be an alternative for me just now.
The original sport exhaust i've got is £1300 from Porsche, Germany. The Dansk is £835.

Hi Ianbadams,

You could try looking up "stevestrange007" on eBay. He has some used exhaust, and I think I saw a sport exhaust too. They're in Lancashire, so not exactly local, but maybe worth it?

Thanks dulmer. That's a good shout for parts. Had a look but he doesn't have any like mine. Going for a second opinion on the split tonight so hopefully they think it's repairable.

Found an exhaust fitter/repairer close to home and they do think they can mend the splits with welding work so putting it in om Friday. Fingers crossed it works successfully.