Exhaust and tunning

[Dave80GTSi]

Opinions on this topic are like belly buttons - everybody has one.

So, since you are asking, here's mine:

1) The cheap Chinese eBay headers seem to be a mixed bag. Some folks love them and have no problems, while others have all sorts of frustrating fitment problems with them. How lucky do you feel today?

I have wasted far too many hours of my life trying to fit aftermarket headers to many other cars which never seem to fit "just right". So for me, the Chinese eBay headers were never even a consideration.

Since the biggest performance gain to be had by deleting the OEM cat manifolds is due to getting rid of their flow restricting cats, I instead went a different path.

I would recommend that you read the text, especially concerning the mini-cats, that I have posted in this ad:

http://986forum.com/forums/boxster-cayman-parts-sale-wanted/73195-sale-hollowed-oem-exhaust-manifolds-complete-mini-cats.html

Considering the modest cost, I would objectively recommend that you go this route, as you will be assured of -zero- fitment problems, while also gaining a significant reduction in heat at this area of the engine.

2) "While you are there", replace the manifold bolts which go into the head with M6 studs and nuts. The next time that you twiddle in this area of the engine, you will be glad that you did:



3) The aftermarket secondary pipes that are out there, once again, anecdotally vary in their fit and quality. If all that you are trying to do is to remove restrictions, then why not simply remove the cats from your existing OEM pipes? Just Dremel off the end cap, remove the cat canister, and then reweld the canister closed. As before, you are guaranteed of a correct fit via the use of OEM parts, and the cost is nothing if you know a guy who has a welder:



4) At this point, you have free flowing manifolds and secondary pipes, all done for almost no money. Before you would go to the final step of replacing the OEM muffler, live with the above improvements for a bit and see how you like them. I would be willing to bet that this gets you where you wish to be. But if not, then one muffler that I really like is the so-called Dansk "sausage". Much more compact than OEM, and it sounds great without droning:



(I bought mine used; dents shown are courtesy of previous owner).

So, there you are. By thinking this one thru and not blindly buying aftermarket parts, I suspect that you will find your own personal nirvana.

Thanks - DM

[Geof3]

Originally Posted by Dave80GTSi

Opinions on this topic are like belly buttons - everybody has one.

So, since you are asking, here's mine:

1) The cheap Chinese eBay headers seem to be a mixed bag. Some folks love them and have no problems, while others have all sorts of frustrating fitment problems with them. How lucky do you feel today?

I have wasted far too many hours of my life trying to fit aftermarket headers to many other cars which never seem to fit "just right". So for me, the Chinese eBay headers were never even a consideration.

Since the biggest performance gain to be had by deleting the OEM cat manifolds is due to getting rid of their flow restricting cats, I instead went a different path.

I would recommend that you read the text, especially concerning the mini-cats, that I have posted in this ad:

http://986forum.com/forums/boxster-cayman-parts-sale-wanted/73195-sale-hollowed-oem-exhaust-manifolds-complete-mini-cats.html

Considering the modest cost, I would objectively recommend that you go this route, as you will be assured of -zero- fitment problems, while also gaining a significant reduction in heat at this area of the engine.

2) "While you are there", replace the manifold bolts which go into the head with M6 studs and nuts. The next time that you twiddle in this area of the engine, you will be glad that you did:



3) The aftermarket secondary pipes that are out there, once again, anecdotally vary in their fit and quality. If all that you are trying to do is to remove restrictions, then why not simply remove the cats from your existing OEM pipes? Just Dremel off the end cap, remove the cat canister, and then reweld the canister closed. As before, you are guaranteed of a correct fit via the use of OEM parts, and the cost is nothing if you know a guy who has a welder:



4) At this point, you have free flowing manifolds and secondary pipes, all done for almost no money. Before you would go to the final step of replacing the OEM muffler, live with the above improvements for a bit and see how you like them. I would be willing to bet that this gets you where you wish to be. But if not, then one muffler that I really like is the so-called Dansk "sausage". Much more compact than OEM, and it sounds great without droning:



(I bought mine used; dents shown are courtesy of previous owner).

So, there you are. By thinking this one thru and not blindly buying aftermarket parts, I suspect that you will find your own personal nirvana.

Thanks - DM

Any significant weight savings with the Dansk muffler?

[Dave80GTSi]

Originally Posted by Geof3

Any significant weight savings with the Dansk muffler?

My OEM muffler weighs roughly 35 pounds.

My Dansk muffler weighs roughly 27 pounds.

[Qckslvr]

So after listening to some more sound clips and reviews of the FVD Brombacher Sound Version, I ordered one. Along with a used set of headers and test pipes.

Now the last set of questions I have.

Should I use a traditional header gasket or the OEM stamped metal gasket. I know from experience that early Fords would crack their manifolds or damage the head if you used a header gasket. It prevented proper heat transfer from the manifold to the head.

Also should I wrap the headers and the test tubes with header wrap? Good or bad idea?

I am keeping my fingers crossed that no bolts decided to break on removal. I am skilled at bolt removal.... but what a pain.

Also are the exhaust manifold bolts/studs 6mm or 8mm? Dave mentions 6mm, but other sites say 8mm. I would like to be prepared for my project.

[Dave80GTSi]

Originally Posted by Qckslvr

Also are the exhaust manifold bolts/studs 6mm or 8mm? Dave mentions 6mm, but other sites say 8mm. I would like to be prepared for my project.

Oops, upon further reflection, I do believe these to be M8. Good catch!

Nevertheless, wise for to remove one and to measure it first to confirm, before you buy replacements.

You should be OK to reuse your OEM thin metal manifold-to-head gasket.

Thanks - DM

[Geof3]

Originally Posted by Qckslvr

So after listening to some more sound clips and reviews of the FVD Brombacher Sound Version, I ordered one. Along with a used set of headers and test pipes.

Now the last set of questions I have.

Also should I wrap the headers and the test tubes with header wrap? Good or bad idea?

Bad. The M96 is somewhat notorious for spark plug tube leaks, and even cam cover leaks to some degree. That oil will pretty much drip right on top of a header pipe potentially, coating the wrap in oil over time. I was going to wrap mine until I researched it and saw a few videos of fires from just this sort of thing. Definitely need to wrap your PS line though, a burn through of that is a major fire hazard. Also helps keep an already hot PS system a little cooler to avoid spill over from your PS res.