[2K3_Boxster_S]

Originally Posted by loosecannon

I had the same problems with the exhaust systems on the market-too heavy and too expensive. I landed up making my own and it was so easy I made 3 versions now to fine tune the sound. For my 2004 986, I ordered 7/8" mandrel bent u-tube from Jeg's and after cutting it in half, I have two perfect exhaust pipes that bolt right up to the pipes left vacant by removing the stock exhaust. I'll try to get pics on here tomorrow but here's what I found: straight pipes without resonators or mufflers make an amazing race car sound-I guarantee that the hairs on the back of your neck will stand up as the car passes 4000 rpm. Imagine a Ferrari F430 and you get the idea. It drones from 2000-3000 rpm, especially with the top up but driving one gear lower makes it easy to live with. I made a resonator by drilling 8mm holes all around the pipes in a section about 6 inches long then slid a 2 1/4 pipe over top and welded it to the inner pipe, this reduced the volume of the drone and on a wide open throttle drive by a db meter 40 feet away, it reached 96 db. Since then I made a 3rd example with the only difference being the size of the resonator pipe increased to 3"-this IMO is nearly perfect. You can sneak up on someone if you keep the rpm low but mash the throttle and it makes an otherworldly sound. It still drones a little from 2000-3000 rpm but would only drive me crazy if I had to listen to it on a road trip, in which case I would just drive fast enough to get above 3000 rpm. I took the car to a local track day and two Boxster owners came up and demanded to know where I got the exhaust. One has commissioned me to make one for him and the other took my 2nd example as a template to make his own. I still have two more mandrel pipes so I can make two more versions. By the way, the whole thing with stainless tips weighs 8 lbs. Also, the tips play a big role in the tone of the exhaust, bigger tips lower the tone, smaller tips raise the tone. I will put the car on a dyno tomorrow night and get video but I doubt the audio will be good quality.

just curious what is your whole setup from headers back? still running stock front CATS??? interested in the dyno results. related to my NHP thread.