Does anyone make a cheap lightweight muffler for the 986?

[sd_boxster]

I'd be just as happy to buy the pipes from an ex-hippie producing bypass pipes in a solar-powered machine shop out of free-range 304 stainless.

[2K3_Boxster_S]

Originally Posted by sd_boxster

I'd be just as happy to buy the pipes from an ex-hippie producing bypass pipes in a solar-powered machine shop out of free-range 304 stainless.

LMAO that's going be in my signature for another forum.

[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.

[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.

[Brad Roberts]

Grant,

I have a Flowmaster setup we have used for years.. makes the car sound like it is doing 9k rpm at 4krpm. Dual in dual out.. and I cap the out and access the center chamber for a center exit exhaust. Light, simple, cheap, effective. I believe I end up with $350 in them.. and they last..

Here it is on a 914.. imagine all this hidden well by the stock Boxster rear bumper. For some reason I have not shot pictures of it on a Boxster.. but Chris Murray runs the same thing on his "Cop car" Boxster race car.









B

[Brucelee]

I like the car but the muffler is pretty ugly!

[Brad Roberts]

300hp 3.6L 993 engine in a 2300lb narrow body 914 It forces you to learn how to drive

Thankfully.. it is all under the Boxster when used. We don't have a lot of room under the rear of the 914!!


B

[grantsfo]

Thats what I'm talkling about. Something cheap, lightweight and functional. That would be perfect.

Originally Posted by Brad Roberts

Grant,

I have a Flowmaster setup we have used for years.. makes the car sound like it is doing 9k rpm at 4krpm. Dual in dual out.. and I cap the out and access the center chamber for a center exit exhaust. Light, simple, cheap, effective. I believe I end up with $350 in them.. and they last..

Here it is on a 914.. imagine all this hidden well by the stock Boxster rear bumper. For some reason I have not shot pictures of it on a Boxster.. but Chris Murray runs the same thing on his "Cop car" Boxster race car.




B

[loosecannon]

Originally Posted by 2K3_Boxster_S

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.

Oops, made a mistake, the tubing is 1 7/8". It's still stock headers and Cats. Anyways, here is a video on the dyno but I couldn't get any numbers because the dyno needs to read RPMs off the crank and that just wasn't possible without removing a bunch of covers. http://www.youtube.com/watch?v=aVMnjSyeyzQ

And some pics:
from behind

Version 2.0 with smaller resonators

Version 3.0 with larger resonators

[myfirstporsche]

Originally Posted by 2K3_Boxster_S

LMAO that's going be in my signature for another forum.

actually, you will have to go to your local organic metal fabricator and buy conflict free fair trade metal to be made into "green" exhaust pipes. look for the certified sticker indicating that no person under 18 made it and the company was paid a fair hourly rate....LOL




I miss Reagan

[zartman456]

What exhaust tips did you use?

[rob76turbo]

2K3_boxster_S: Did you put your boxster on the dyno with the NHP exhaust yet? Interested to see the results. How does it sound? I know that $895 is a lot more than what the target is here....but it looks to be made very nicely.

Loosecanon - I love the simplicity of your design #3. What kind of dollars if you build another one? I want to shed the pounds and would love to make it a bit louder too. HP increase....that is the icing on the cake!

[loosecannon]

Originally Posted by rob76turbo

Loosecanon - I love the simplicity of your design #3. What kind of dollars if you build another one? I want to shed the pounds and would love to make it a bit louder too. HP increase....that is the icing on the cake!

For me to build another one or for you to build another one? Summit racing sells the pipe for about $18.00, the stainless tips are around $30.00 and the larger pipe for the resonators is about $10.00. Any local guy with a welder and drill press can make it for you. The inside pipe is 1 7/8" and the outside pipe should be 3" or greater.

[rob76turbo]

[QUOTE=loosecannon]For me to build another one or for you to build another one? Summit racing sells the pipe for about $18.00, the stainless tips are around $30.00 and the larger pipe for the resonators is about $10.00. Any local guy with a welder and drill press can make it for you. The

Thanks! I think I can find someone local that can weld this.
Question; how did you fit the new exhaust up to the cat-back tubes? Weld again?

[2K3_Boxster_S]

[QUOTE=rob76turbo]2K3_boxster_S: Did you put your boxster on the dyno with the NHP exhaust yet? Interested to see the results. How does it sound? I know that $895 is a lot more than what the target is here....but it looks to be made very nicely.
QUOTE]
still Fully stock. i keep getting sent out of town for my work. I also still haven't got an accurate (baseline) dyno of the full stock setup yet. It will be back on the dyno for the baseline middle Aug. then my setup will be full headers, bypass mids and the NHP exhaust. let you know when i get there