Bye Bye Borla, Hello Brombacher
 

Having punched through my 986 winter project list ahead of schedule, I decided to tackle an issue that is causing real problems for my tinnitus (have I mentioned I'm old??). I absolutely love the sound of my Borla exhaust that was already installed on my 550SE when I bought it last year. However, after a year with the car it's clear that the 2,500-3,000 rpm resonance has been adversely affecting my tinnitus (and the muffler construction come to find out).

Having some experience with exhaust systems across the last four decades or so, I decided that I could add a system cross pipe immediately prior to the outlets (the only practical place) to help cancel the harmonic vibrations created by having two sets of three cylinders isolated. Checked under the car and it was doable:

http://986forum.com/forums/uploads02...1518388783.jpg

Next step was to check the Borla with my infamous "whack" test to make sure everything was tightly in place in the cans and mounts. It was here that I found that the right (passenger) can failed the test. Mega vibrations when the can was whacked with the base of my fist. Not the mounts, not the clamps, not a cat shield, it's inside the (non serviceable) can. It's terminal.

I still have the original muffler, hardware and 550 SE tip, but the muffler has some northeastern induced rot at the seams. I'll keep it in off chance I decide to ever sell the 550SE (not likely).

So, after much research across the web / YouTube / etc (thanks 10/10ths for the Brombacher shoutout), I've decided that I will order the Brombacher "Sound Version" tomorrow morn. Expensive, but what the hey, I can't take it with me. Dansk sausage was less expensive and a close runner up, but the Brombacher is calling me.

More to come after it arrives!

SpeedArt
 

I believe that the Brombacher is manufactuured by SpeedArt, I have the same unit you order and I believe that you are going to love it!
PS: And yes, cero drone...

Hi Gilles, I saw your earlier comments to 10/10ths while I was doing my research. I checked out the SpeedArt and I think you are right that they are the same unit. I also watched the FVD YouTube videos for a sound check. It’ll be a dream come true to have an exhaust built this well that sounds this good, with no drone. For others who are interested, here’s the link to 10/10th’s original thread (which has pics and the link to the FVD videos):

http://986forum.com/forums/performance-technical-chat/62115-fvd-brombacher-sound-version-muffler-installed-wow.html

I ordered the Brombacher from FVD this morning. Rhonda is great and she -for real- really knows Porsche. The ‘sound version’ is not in stock in FL, but they have it in the Germany warehouse. I should have it in hand no later than Friday, Feb 23rd. Can’t wait. :cheers:

THIS THREAD IS EVIL! I DID NOT need to hear that exhaust. My wife will be mad!

Welcome to the DarkSide :eek::D

Well, I think I owe an apology to Borla. Pulled my Borla exhaust today in prep for the Brombacher install, did my whack test again with the Borla suspended several different ways free standing and . . . no vibrations, solid as a rock. Hmmm, back under the car and I discovered the vibration appears to be from the heat shield immediately in back of and above the Borla’s right can location. Oops, too bad the Brombacher is already on order (not :D)

Anyway, because the Borla seems a-ok I’ll put it up for sale at some point. It’s a drone king at any rate and I’ll recommend to anyone who purchases it to at least weld in the crossover pipe in an attempt to quell the drone. If I had more time, I’d experiment myself just for grins but the to-do list is stacking up with spring on the horizon (kart prep for the 2018 season, visitors, etc.). Here’s a pic I snapped today:

https://uploads.tapatalk-cdn.com/201...dfcff4604b.jpg

More to come when the Brombacher arrives. Until then I’ll just keep watching the YouTube vids.


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Update on mine....
 

...I bought some Circuit Weeks secondary cat delete pipes from an inmate here and they, combined with the FVD muffler are street exhaust heaven.

The secondary cat delete made the exhaust QUIETER inside, yet LOUDER outside, and completely eliminated the drone. There was still a very faint drone with the FVD. It is now completely eliminated.

BUT, when you get on the throttle, it sounds awesome.

Can you post a sound clip inside and outside? There is another thread about the cat delete and I have been considering this setup.

No...
 

...sorry.

Good luck.

On the Brombacher... how much, if any, weight savings might there be?

Brombacher spec says 23lbs. I’m going to weigh the stock muffler and the Brombacher with my digital luggage scale side by side when the Brombacher arrives.

Sound like the one on ebay, I think I bought the 6 spd trans from that boxster S, correct me if I'm wrong, thanks.http://986forum.com/forums/uploads02...1519048477.jpg
http://986forum.com/forums/uploads02...1519048512.jpg
http://986forum.com/forums/uploads02...1519048546.jpg

Hi Frankle, not sure what you are referring to, but I did not buy the Brombacher muffler used on eBay. I bought it new from FVD in Florida.

Ok, my mistake, cheers

It’s here! Unfortunately so is the snow that just turned into ‘winter mix’. I had to meet UPS in town. They couldn’t make it up the road that connects to our road, much less our road itself. Also brought up a ‘next day’ package for our neighbor on the connecting road so they wouldn’t have to wait until next week for it. Logistics can be tough up here this time of the year.

Great packaging by FVD and great service by their Florida distributor and CSR (Rhonda).

https://uploads.tapatalk-cdn.com/201...6028108651.jpg

https://uploads.tapatalk-cdn.com/201...9f859e73b6.jpg

https://uploads.tapatalk-cdn.com/201...5dfe843da2.jpg

Taking the weekend off, so no work on the 986 until Monday.



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Congratulations Oldcarguy!

I hope it sounds as good as it looks! Look forward to hearing it and your comments.

Ocg.....
 

....Winning!!!


:cheers:

There is something just wrong when a shiny object like that looks "sexy". Sweet! Videos... we need videos.

One reason......
 

...the FVD muffler is so expensive is that it is made out of T316 Stainless instead of T304 like the Borla, et. al.

Shiny. Stays shiny. also give better quality sound than T304.

:cheers:

Congrates, and me too ready for comments! :D

I almost went for a fabspeed being they are on sale, would cover shipping. But i really like the sound clips of the fvd. Beutiful piece of metal.:cheers::cheers:

Could you post photos looking into the inlet pipes and tips? I just received a Dansk sound version and was surprised to find it is a straight through perferated pipe design. Not chambered like oem.

Internal pics
 

Here's the best I could do with my iPhone and a flashlight.

The Brombacher appears to be a 'hybrid' design. Each side is straight through a perforated pipe to its own outlet, but there is some type of crossover pipe or connection pipe leading into some other internal structure inside the muffler (crossover, chambers + crossover, portal into another dimension, . . . ???).

The first pic shows the bend into the outlet pipe and the interior connection pipe leading to ???:

http://986forum.com/forums/uploads02...1519484744.jpg

The second pic is a better shot of the internal pipe join:

http://986forum.com/forums/uploads02...1519484810.jpg

The third pic is shining the flashlight into the tail pipe outlet and taking the pic from the inlet. This confirms the 'straight through' aspect for each side in addition to the internal connection pipe:

http://986forum.com/forums/uploads02...1519484938.jpg

Each side is identical except for weld variance. Let the speculation begin :D

Dansk
 

Thanks for obliging my curiosity!

For comparison, here are shots of the Dansk 94.300SEXP.

http://986forum.com/forums/uploads02...1519526898.jpg

The inlet bends slightly upward, passes through ~5" of perforated pipe, then sweeps back downward, crossing through (or equalizing with) the other bank pipe before exiting.

http://986forum.com/forums/uploads02...1519527150.jpg

This muffler accepts the stock 03-04 removable exhaust tips. It's going on my '99 2.5l, so I'm happy to be able to mount an oval tip.

Can't wait for spring to bolt this guy on!

Muffler weigh-in
 

You’re welcome. Interesting to see that the Brombacher and Dansk do have different internal designs.

Here’re the weights for the three mufflers I have in hand. All weighed with our trusty electronic luggage scale which has proven reasonably accurate across the years.

- Borla: 19.7 lbs (with welded c pipes to connect to cats and welded bracket - ready to install, no additional parts required except cat pipe clamps). To note, the Borla welded bracket bolts directly to the transmission, so there are a few lbs of additional savings because the heavy Porsche transmission bracket and muffler top bracket/isolators are deleted. Mounted, the Borla is easily 10 lbs lighter than stock.
- Brombacher: 24.5 lbs (without top bracket/isolators, clamps or c pipes)
- Stock 550 SE: 27.4 lbs (without exhaust tip, top bracket/isolators, clamps or c pipes)

So, installed, the Brombacher is ~4-5 lbs lighter than stock w/tip and it is ~5-7 lbs heavier than the Borla according to my measurements. YMMV.

Good stuff. I still have my stock 550 muffler and I mounted the SE tip on my Porsche tribute wall. I never took the time to weigh the FVD or the stock muffler. Nice to know I dropped a few pounds outta my rear end. ��

The higher grade of stainless steel let’s them drop a few pounds and maintain strength while keeping the drone away. Remember that the stock muffler design is part of the harmonic balancing of the power train. That’s why all those aftermarket two muffler setups don’t work. This is well documented in every Boxster history book and and in “Excellence Was Expected.”

Installed the Brombacher today. Started the 986 on the Quickjack to check for leaks (none). Sounds more ‘solid’ and much quieter at idle than the Borla. I can already tell that I’m going to be a happy camper.

As an aside, I really don’t see how anyone can install a standard size muffler like this without removing the rear bumper cover, rear bumper w/heat shield and the rear fender skirts w/heat shields. Especially because these parts are so easy to remove.

Here’s a couple of pics.

https://uploads.tapatalk-cdn.com/201...62f40ff4fc.jpg

https://uploads.tapatalk-cdn.com/201...a8089f39ba.jpg


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I did this. It got to the point where I knew it would be so much easier without the bumper on but I figured I had gotten that far with it on that I might as well finish it with it on, if that makes sense. It was the biggest PITA job I have ever done on any car. I vowed to never touch the muffler ever again. But if I were, I'd probably go with one of these or the fister.

Let us what you think of it!

It's going to be in the mid 50's for the next few days......So you better take it out for a spin with the new muffler :D

I’d love to except. . .no wheels. They’re ready but I can’t make it to Albany until Wednesday to pick them up :cool:

Will do. Kudos for being able to do the muffler change with the bumper on :cheers:

Now....
 

...get ready for those FVD tips to turn gold after a few cycles.

Uggg. If I could get the day off from work i'd drive down there and put my wheels on your car.

I did replace my original muffler with PSE without taking rear bumper off.... My axles and shocks were out to replace wheel bearings so some access but still took some swearing, and did I mention it is sooo heavy?

But you know it is worth the effort, a year later I still smile just looking at it, and it sounds very pleasing.

So yours is internally bypassed, right? Looking forward to sound clip!

Do we get a sound clip soon? Lol. Looks nice mounted up.

Old Carguy: After researching and synthesizing the data regarding which exhaust to upgrade to, uou've inspired me to decide on my exhaust upgrade--Brombacher it is!

Hi Ciao, I hope you’ll be as happy with your choice as I am. I almost went with the Fabspeed but I just liked the sound and design of the Brombacher better (based on the web videos I found), and the positive comments from 10/10ths and others :cheers:

Thanks, sound video coming as soon as I can convince my camera person to join me on a quick run!

I just ordered a FVD Brombacher (sound version). Going to be interesting to hear it in action! 🤘🤠🤘

You are going to like it..!

I will be puting mine for sale shortly as I am no longer have my 987.. (long and sad story) :(

Haven’t forgotten the sound clip. Our 1/2 mile private road still has sheet ice on some of the steepest sections :( I’ll make and post the sound clip when spring finally makes its belated arrival.