Removed Intake Muffler, Sounds great! - 986 Forum - The Community for Porsche Boxster & Cayman Owners

CJ_Boxster · 02-25-2008, 11:54 AM

Hey guys, My saturday project was to remove the sound muffler from the end of the intake tube near the throttle body.

It sounds GREAT! Since i already Desnorkeled, i already get that great intake growl from 4800 rpms and up but now with the intake muffler removed, i get this great deep growl at lower rpms that i can sometimes feel in my chest and back which starts at a suprizingly low 2800 rpms.

Since i couldnt find a plug to cap off the intake tube where the muffler once connected to, I bought a 60 second epoxy from autozone, mixed that in a plastic deposible cup which i cut 2/3rd's of its height away and plunged the portal where the muffler once attached into the cup full of epoxy and let it set for 3 minutes then pulled the cup off and let it dry for about 20 more minutes before installing... If you want more growl and dont want to buy a $300+ intake which is basically a peice of tube, then i recommend this mod for you!

Blkboxster · 02-25-2008, 12:03 PM

Sweet, lol how do i do this mod?, can you make a dyi, does it cause a Cel?

thanks

CJ_Boxster · 02-25-2008, 12:23 PM

Since i dont have a camera on me ill explain what you need to do.

Parts & Supplies
-8mm socket
-10mm socket
-Ratchet + extension
-Pliers
-Plastic disposible cup
-60 second quick drying Epoxy

Instructions

1) Place top in service mode and remove engine cover.

2) Uplug & Remove MAF

3) Remove hose clamps that hold intake tube to airbox and throttle body.

4) Remove 10mm bolt that holds intake muffler to engine lift bracket.

5) Now, the tricky part... Removing the Intake tube, It wont just lift outta there, the muffler is so bulky that it'll prevent it from coming out UNLESS you pinch the clamp that holds the muffler to the intake tube while you pull the intake tube out.... This will cause the muffler to slip off the intake tube thus alowing the intake to come out of the engine bay, then you can remove the muffler from the engine bay.

6) Now clean the inner and outter surfaces of the neck of the intake where teh muffler attached.

7) Get a plastic disposible Dixie or similar cup and chop about 2/3rd's of its hieght away.

8) Now start mixing your epoxy inside the shortened cup for about 15 seconds with a stick or similar device

9) Now plunge the intake tube's muffler neck into the cup of epoxy and let it set for about 3 muntes or until cured then let it sit for 15 more minutes before reinstalling the intake tube.

10) Now reinstall everything (minus the intake muffler) in reverse order

Alittle FYI, this was done to a 1997 boxster and some newer boxsters (E-gas versions) may not be able to do this mod cause of a redesign in the intake tube. In newer boxsters the intake muffler is integrated into the intake tube and isnt removable.

DISCLAIMER This forum nor I are responsible for any malfuntions, mechanical failures and deaths which may occur by doing this mod. Mod/Hack at your own risk.

CJ_Boxster · 02-25-2008, 12:24 PM

Quote:

Originally Posted by Blkboxster

Sweet, lol how do i do this mod?, can you make a dyi, does it cause a Cel?

thanks

Oh yeah, as for check engine lights, i dont know cause i already have one due to a secondary air injection gremlin that i have yet to fix but ill recheck the computer for any new codes later today.

porsche986spyder · 02-25-2008, 12:59 PM

I have the True Flow intake which also deletes this small muffler as you call it. No cell lights will come on. Its really nothing more than a silencer along the intake tube. I think if you look at Home Depot you should be able to find a circular cap/plug for that size hole. It will make your car growl more. Here is the area he is talking about. It looks like a small box that is connected to the intake tube. Inside of it you will find a white foam silencer. There really is no need for this part other than to quite down the noise level. In fact, this area being removed should provide better air flow. I would suggest buying a 90 degree elbow bend plastic tube from Pepboys and making your own intake tube. It's pretty easy.

This will delete number 6, 7 & 8.

986Roadster · 02-25-2008, 01:09 PM

thank you for the picture. can't i leave it open, why even glue a cup to the end, if it's open anyways. does this make sense. if i get an elblow put on, i am still leaving it open. or am i missing a step. i am pulling the silencer out of the box, so the box is now empty. will i be putting the box back also. dumb questions...i guess when i open, i should be able to figure it out better.

porsche986spyder · 02-25-2008, 01:24 PM

Quote:

Originally Posted by 986Roadster

thank you for the picture. can't i leave it open, why even glue a cup to the end, if it's open anyways. does this make sense. if i get an elblow put on, i am still leaving it open. or am i missing a step. i am pulling the silencer out of the box, so the box is now empty. will i be putting the box back also. dumb questions...i guess when i open, i should be able to figure it out better.

No. You are right. If you buy an elbow silicone cupler and also buy an extra clamp, there is no hole left and no need for messing with epoxy or anything like that. Look at this picture. Simply cut the tube at the ribbed part at the end going towards the throtle body and add the new elbow at that end with the new clamp.

CJ_Boxster · 02-25-2008, 03:33 PM

Quote:

Originally Posted by 986Roadster

thank you for the picture. can't i leave it open, why even glue a cup to the end, if it's open anyways. does this make sense. if i get an elblow put on, i am still leaving it open. or am i missing a step. i am pulling the silencer out of the box, so the box is now empty. will i be putting the box back also. dumb questions...i guess when i open, i should be able to figure it out better.

What my directions say todo is to remove and discard part number 6, 7 & 8 completely...
The Epoxy in the cup will be jammed onto the opening circled in the picture... However once the epoxy is cured abit and almost solid, you peal the 2/3rd size cup off and the epoxy should stay behind stuck onto the opening circled in red.

986Roadster · 02-25-2008, 12:58 PM

interesting! now the part that i don't understand. the plastic cup and epoxy....am i glueing the cup somewhere...kind of confused. circular cap/plug doesn't help. if you could please explain this further. or pics would be amazing!!

i'm jealous i want to try tooo!!

i'm fairly good with my hands, so if you could make me understand in a better way.

Shehadehd · 10-13-2013, 03:13 PM

So I removed the intake tube on my 2000 boxster and it looks a lot different than the ones described here. I wonder if that bulky portion is the resonator and if it will make a difference to cut out and replace. Can anyone chime in who knows something. Thanks.

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Topless · 10-13-2013, 03:53 PM

Definitely part of the intake tuning. It looks like an expansion chamber to change the resonant frequency of the system. You get to decide if it is important on your car. A brief reference on similar designs:

Patent US5572966 - Method and composite resonator for tuning an engine air induction system - Google Patents

Shehadehd · 10-13-2013, 04:41 PM

Quote:

Originally Posted by Topless

Definitely part of the intake tuning. It looks like an expansion chamber to change the resonant frequency of the system. You get to decide if it is important on your car. A brief reference on similar designs:

Patent US5572966 - Method and composite resonator for tuning an engine air induction system - Google Patents

I appreciate the help. I think I'll leave it for now. If my friend, who did the deletion, has a much nicer sound than mine, maybe I'll consider retrofitting the old intake and see how it pans out in the 2.7l engine.

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epapp · 10-13-2013, 06:11 PM

Yes that friend of yours just did the 2.5L resonator delete. I capped it with a rubber 1.5" cap from the hardware store meant for plumbing (in the section with PVC etc.).

At first it seemed to be not much of a change, but then you hit the gas at 3000rpm in 2nd gear and you really notice the difference. It is surely a nice sound. Louder than just de-snorkeling. If you hit the gas in first gear off the line, it becomes a gut wrenching intake beast.

No...its not drone-y or fart cannon sounding. It sounds like a beast taking a huge gulp of air.

Shehadehd · 10-16-2013, 09:01 AM

Just wanted to update the thread for anyone with a 2.7l who thought it might be possible to use the 2.5l air intake to do the resonance chamber deletion; it isn't. Well, at least without some modification.

The intake tubes have different size fittings, with the 2.5l being slightly larger, in addition to a different form factor that prevents the older intake from fitting into the 2.7l. Basically, the amount of work it takes to retrofit the air intake would be better spent modifying the current one or make an entirely new intake track (at least IMO).

Sometime this week I'm going to head back to the salvage yard to see if I can get the 2.5l intake swapped for the proper intake. After modifying it I'll report back any breakthroughs.

jaykay · 10-30-2013, 11:44 AM

The throttle body position for the 2.5 is much different than the 2.7. In the stock configuration the 2.7 looks quite similar to the 3.2 intake plumbing as far as I recall. The 2.5 tb is oriented almost traight back.

The easiest route to remove the muffler or helmholtz chamber would to cut it off just be before the expansion (2.7 and 3.2) and fit a 45 degree elbow with appropriate leg lengths....or something close to it.

If you are really going to do this please do some timed accelerations from 3K to 4K rpm before and after the chamber deletion. I would be interested in throttle response times. Yes this will get you more sound but ....will it affect performance?

I personally would leave the chamber in there if you can...you are not piping a ipd plenum or other but I definitely like some test engine acceleration times in 3rd and fourth gear from 3K before and after.

One of the reasons I have not put in a 987 air box in is that it requires the removal of the integral helmholtz chamber for fitment. I don't don't want to do all that work only to find a performance loss due to poor acoustics

CJ_Boxster · 10-02-2014, 05:38 PM

I posted this so long ago and I'm embarrassed at how poor my explanation was... in a nutshell, i remove the muffler and plugged the hole on the intake pipe with a cap from a Gatorade bottle.

I was but a 25-27 year old baby when I first posted this wild discription that i called a DIY back in 2008, Im 32 now... without a boxster anymore. I was just overly enthusiastic when i first posted this thread, i meant well but I should have taken a sedative when before posting

Anyway, It was nice stopping in for a bit.

tommy583 · 05-23-2016, 03:33 AM

Brad did you ever get the dyno readings from this mod?

I bought a spare intake tube from Woody and think i'm going to try this. My plan is to cut out the section that has the hole for the muffler. Then use a silicone coupler join the two sections together. If it loses power, throws a CEL or doesn't sound better i'll just put the old one back in.

Ben006 · 05-23-2016, 05:50 AM

You'll loose a bit of low end torque, get a slight increase in top end, and a different noise (when I did I lost the growl at low rpm for a slight increase of sound at higv rpm, but did not get a better sound)
But if you think about it, you spend more time between 1800 and 3000 than above 4500, so it won't benefit you everyday!

If you can do it for cheap, do it, you'll see for yourself if you like it

It won't light the CEL or make the car run rough.

Ben