Performance Exhaust and Header for Boxster

[racer_troy]

...that has not already been said in the thread...I'm new to the board (will do intros later) but just have to say Holy Cow...I've been around ktmtalk.com thumpertalk.com, and vwvortex.com and never have i seen a thread like this before...just a few questions...

Randell, nice write up and incredible job bitting your tongue while all the flames were blasting past your head...kudos! Anyway, how many miles have you put on your '97 since the install? Are the welds still holding up? No rattles or leaks? I'm interested in the added performance, but drive appx 800 miles per week and just can't have something under there that I have to worry about tackin' up every other month.

Also, anyone out there running one of Che's systems with and EVO intake or even a BMC panel? How about chip programming? Have we seen any results with GIAC? REvo?

Thanks in advance,

--troy

[DAAM421]

Also, anyone out there running one of Che's systems with and EVO intake or even a BMC panel? How about chip programming? Have we seen any results with GIAC? REvo?

Thanks in advance,

--troy[/QUOTE]
k&n filter ++++++

FABSPEED CAT BYPASS PIPES ALSO INSTALLED,along with che 's great cat back...will be picking up headers from him. well when they are out for 03 2.7

[RandallNeighbour]

Troy, I have only had it on two weeks and put 100 miles on the car. Just enough to fall in love with the extra power and lovely exhaust sound. No new leaks to report!

[racer_troy]

Thanks Randell...keep us up to date...I'd be interested to now if and when any leaks, rattles, or cracks develop...

cheers,

--troy

[delubozparts]

Hello Everyone,

racer_troy had step up & willing to take this Header Dyno experiment for his 2000' Boxster 2.7L I choose racer_troy due to his Boxster is all stock & can do the Installtion & Dyno next week. I will ship out today & he will keep everyone post with update. Thank you !!



Best Regards,

Che

Originally Posted by racer_troy

Thanks Randell...keep us up to date...I'd be interested to now if and when any leaks, rattles, or cracks develop...

cheers,

--troy

[blinkwatt]

Originally Posted by RandallNeighbour

Troy, I have only had it on two weeks and put 100 miles on the car. Just enough to fall in love with the extra power and lovely exhaust sound. No new leaks to report!

How much more power does it feel like the car has? Is it noticeable in everyday driving?

[RandallNeighbour]

Originally Posted by blinkwatt

How much more power does it feel like the car has? Is it noticeable in everyday driving?

Dude, that first one is a really hard question to answer. I dunno. More power, but not tons more. Just a little more grunt and I get down the road a little faster.

As to the second question, yes, it is noticeable if I am driving it to the store or to the office or taking it out for a spin. I lost no low end torque or HP as is the case with some aftermarket headers.

I think the most fun of all of it is when I go under and overpass and nail it. The sound that reverberates off the walls and freeway above is absolutely de-light-ful!

[yfz/700R]

Originally Posted by RandallNeighbour

Dude, that first one is a really hard question to answer. I dunno. More power, but not tons more. Just a little more grunt and I get down the road a little faster.

As to the second question, yes, it is noticeable if I am driving it to the store or to the office or taking it out for a spin. I lost no low end torque or HP as is the case with some aftermarket headers.

I think the most fun of all of it is when I go under and overpass and nail it. The sound that reverberates off the walls and freeway above is absolutely de-light-ful!

doesnt the 2.7 have about 15 more hp/tork than the 2.5? is there much of a difference in acceleration between the 2.7 model and the 2.5 model?

[blinkwatt]

Originally Posted by yfz/700R

doesnt the 2.7 have about 15 more hp/tork than the 2.5? is there much of a difference in acceleration between the 2.7 model and the 2.5 model?

That can be debated for days....Some say the 2.7s are faster off the line,and that the 2.5 are faster at highway speeds(possibly due to a change in gear ratios). Some say they felt no difference between the engines,some say its night and day......

[racer_troy]

Hey Board members,

The first update I have is just timing and planning to let you know what we are looking at.

Firstly, this is just a header mod and not the full deal that Randall got with header and cat back.

Timeline
Monday, 10/16
- Header arrives at O'Daniel's Porsche
- GIAC flash load at Fall-Line MS in Chicago (Naperville I think)

Tuesday, 10/17
- Dyno pull at EPP in Columbia City, IN
- - Stock motor
- - GIAC software with stock motor

Wednesday, 10/18
- 8am install of header at O'Daniels in Fort Wayne
- May actually work a bit in the early afternoon
- Dyno pulls at EPP:
- - Stock engine map with Che's header
- - GIAC engine map with Che's header


Scope
Secondly, I have a EVOMS intake system on the way from Suncoast Porsche that I will install next week. I will have to schedule install and dyno time for this piece as well. Will advise.


Thridly, unfortunately, I will not be able to evaulate Che's fully system, however, I'm checking around with other retailers (FVD, EVOMS, PerformanceProducts/Autonation) to see what kind of deal they can cut me on some of the other proven cat-back systems. Initially, I wasn't sure if I was just going with a stage 2 header/remap/BMC filter panel or a stage 3 header/reamp/intake/exhaust. Somehow, the devil got the best of me and I ordered the EVOMS intake. So right now, it looks like i'm going stage 2.5 for a bit as the 3-4 dyno runs are going to run appx $300-$400 bucks ($35 tie down fee plus 3x runs for each system configuration).

I only wish I had the resources to do a full-on comparison of exhausts. When I was racing bikes, we would find the expansion chamber diameters and transitions that would make the best usable power off idle through mid/top-range (dyno port). After that, the final top end tuning (post jetting) would come down to trying different muffler (effectively stinger) lengths (litterally starting long and hacking them down) to find what we should run where (Fla. sand, east coast rock, midwest loam, Southern Ohio mud, South west desert, Idaho dry-slick, et. al.). Anyway, perhaps someday I'll stumble upon a pile of 986 cat back systems and I can finish this experiment by seeing what systems truly enhance the upper mid-top and don't detract from the off-idle through low-end grunt.

Preliminary Guesses
My best estimates believe we will see SAE corrected BHP of around 235 with torqure figures around 210 ft/lbs assuming a straight 15% drive train loss. Net gain will be appx. 18bhp and 18ftlb with the full-on stage 2.5 system. Time will tell. Any others care to guess?


Let me know if you have any questions or anything else you would like to see.

Otherwise, stay tuned...

Cheers,

--troy

[edevlin]

Racer Troy, you are going about this in a much more organized fashion than I did, but your estimates of numbers are what I have found as well. The mods on my 2.7L Boxster are still in process, I am having a final remapping of my AutoThority chip, hopefully next week. I will run a dyno on it when it gets done.

The mods I have done inclued a TTP intake, TTP headers and Cats with a stock muffler. I am also using a AutoThority ECU chip. The car is running great, but the dyno shows it is running a little rich over 5K, so the chip will be remapped to take that into account.

Car sounds great, and is quite responsive with a very flat torque curve from a little over 2K to redline. I am seeing 202 HP and 169 ft/lbs on the dyno which works out to about 237 hp and 198 ft/lbs at the crank (figuring a 15% loss). I expect to pick up another 5-10 hp when the chip gets remapped for my intake and exhaust.

When the dust settles, these mods are going to end up costing me about 200.00/HP, so they are not cheap, but I have been having a great time messing with the car for the last couple of months, and it runs like a dream...... at least so far.....

Ed

:dance:

[blinkwatt]

*I tracked someone down through eBay feedback who had purchased the headers & exhaust from a different seller but from the same manufacturer as where "Che" buys his parts.

I sent;
"Hey I was wondering how those aftermarket headers and exhaust are holding up on your Boxster. I'm looking into the same parts to put on my 99'...."

I received;
"Actually the muffler did not fit at all unless major modifications or custom brackets..then my mechanic thought the headers were ok but they dont seal properly and one side leaks..so we are taking those off...I am going to get a dansk muffler and the schnell headers...I would stay away from these knock off products...."

I edited out a couple of sentences that weren't related to the headers & exhaust.

If anyone else has bought these parts and installed them with a bad/nuetral/good expierence please let us know. Knowledge is power.

[delubozparts]

Originally Posted by blinkwatt

*I tracked someone down through eBay feedback who had purchased the headers & exhaust from a different seller but from the same manufacturer as where "Che" buys his parts.

I sent;
"Hey I was wondering how those aftermarket headers and exhaust are holding up on your Boxster. I'm looking into the same parts to put on my 99'...."

I received;
"Actually the muffler did not fit at all unless major modifications or custom brackets..then my mechanic thought the headers were ok but they dont seal properly and one side leaks..so we are taking those off...I am going to get a dansk muffler and the schnell headers...I would stay away from these knock off products...."

I edited out a couple of sentences that weren't related to the headers & exhaust.

If anyone else has bought these parts and installed them with a bad/nuetral/good expierence please let us know. Knowledge is power.

Hi blinkwatt,

First of all how can you be sure that other seller used the same manufacturer source ?? Can't judge the Book by its cover. Of course theres other manufacturers had the same ability to produce the same products but not necessary same as mine. This is very Long forum Posting maybe you had missed from the beginning, as I stated very early in my Posting these Exhaust & muffler are manufactured from my family operation. I've been working very hard to proved the Exhaust & Header in this forum,by providing actual results & feedbacks from members of this very own forum. Looks like the other seller are not competant enough to take care of defective product & caused a Unhappy Customer, as I had confidence to Offer Full Refund & fitment Guaranteed for my customers. Just want to Clearify, after all your intention is Cool. The more informations provided would benefit everyone in this forum.



Che

[BoxsterSbob]

Hi, is there a cut away view of the Cat-Back system?


many thanks
bob

'04S
Borla
BMC

[delubozparts]

Originally Posted by BoxsterSbob

Hi, is there a cut away view of the Cat-Back system?


many thanks
bob

'04S
Borla
BMC

Hi Bob,

Currently I don't have any cut away view of the cat-back system, too expensive to cut a brand new exhaust. I will do so in future if I come across a defective system from production.



Che

[racer_troy]

Goodmorning,

Day two of the install is taking place. After through review of the PET it looks like there were several variations of o2 sensor locations. On my MY00 I have 2x o2 sensors per header. This is not the most common arrangement as I understand. We will be evaluating a couple of options this morning:
1. Place an o2 bung upstream of Che's and risk low efficiency.
2. Have GIAC program steady efficiency parameters for the pre-o2 on the secondary cat (first ceramic cat in the system, cloest to header).

Stay tuned, will advise,

--troy

[RandallNeighbour]

In a most amazing fashion, my rear trunk is now so cool that I can put most anything back there and it does not boil or melt due to the heat the stock muffler was giving off.

DelubozParts' sport exhaust not only sounds great, it's SUBSTANTIALLY cooler than the stock muffler. I knew it was smaller and had two chambers, but I didn't expect such a dramatic drop in trunk temps.

Last year, I drove the Boxster to California and I actually melted a tennis shoe lace into the sole of the tennis shoe because it rode in the rear trunk of the Boxster in summer weather.

This weekend, I drove to central Texas (4.5 hours) and as I unpacked the car I realized that the trunk wasn't hot enough to deliver pizzas any longer.

:dance:

Che, you need to advertise this about the mufflers you sell. It's worth something to those that have melted ice cream on the way home from the store, etc.!

[delubozparts]

Originally Posted by RandallNeighbour

In a most amazing fashion, my rear trunk is now so cool that I can put most anything back there and it does not boil or melt due to the heat the stock muffler was giving off.

DelubozParts' sport exhaust not only sounds great, it's SUBSTANTIALLY cooler than the stock muffler. I knew it was smaller and had two chambers, but I didn't expect such a dramatic drop in trunk temps.

Last year, I drove the Boxster to California and I actually melted a tennis shoe lace into the sole of the tennis shoe because it rode in the rear trunk of the Boxster in summer weather.

This weekend, I drove to central Texas (4.5 hours) and as I unpacked the car I realized that the trunk wasn't hot enough to deliver pizzas any longer.

:dance:

Che, you need to advertise this about the mufflers you sell. It's worth something to those that have melted ice cream on the way home from the store, etc.!

Hi Randall,

Wow this exhaust didn't turn your trunk to oven,definitely a Interesting update. Unfortunately I don't have these exhaust & header back in days when I had my Boxster, everything for Porsche cost arm & leg.

Member Darin & kwu just order the exhaust today, I even marked the 2 Holes for drill guide. They should receive the package in next 3-4 days, alsow Darin will Post a update sound clip (ie stock sound / After Exhaust installed sound).

The sale is slowly, I'm very Happy with 986forum.com members are ordering due to the fact of the Performance & Quality + Pricing.

After all I can't make it without your help in the first place, always my Buddy in Houston.

Keep in touch !



Best Regards,

Che

[racer_troy]

OK...well...I've only a few minutes here so I'll be as brief and to the point as possible (which is sometimes difficult for me...)

The header install went well. As noted below, I've an o2 sensor issue to work out that is as of yet, unresolved. I will be reviewing the PET's once again and looking to see if any of the MY01 and later sensors have longer leads to allow plugging in pre and post primary cat. I'm scheduled to do this on Monday the 30th and then back on the dyno for the final numbers Nov 2.

So....having said that...I do have some informaiton from a baseline pull and Che's 2.7L header system.

Here's the baseline:

178.3bhp @ 6265rpm
157.8lbft @ 5178rpm

This shows appx 17.8% drive train loss assuming the car was producing all 217bhp as reported by the factory.


Che's headers:

184.6bhp @ 6386rpm or net +6.3bhp
155.4lbft @ 5700rpm or net -2.4lbft

This is not bad on the HP side and as expected with the torque. I've some theroies and more photos to share later.

Unfortunately, due to the o2 location issues on the MY00, we used some of our alotted time to problem solving and less evaluation. I'll try to get the full on test report soon.

Feel free to start the questions.

--troy

[edevlin]

Interesting numbers for the baseline pull on the 2.7L. Does anyone else have baseline dyno numbers for a 2.7L? I had some mods done on my 2000 Boxster before I found a dyno, so I lack a baseline (really kicking myself on that one).

I have been assuming a 15% loss in the powertrain. I believe the numbers racertroy got, but a 17.8% loss seems high to me. Any ideas why there would be that much drivetrain loss?

Ed