EDIT 10/29/08..........
Updates added on page 2.
ORIGINAL POST
I guess I should start by saying that I have never done, or had done, this type of work before. I don't weld, not exactly sure if I understand what 'off-throttle response' means and half the time I need to ask my neighbor to help me get my kids 2-stroke dirt bike to start.
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I do however, have a lot of trust in the advice of my fellow R-owners and I'm not afraid to take a chance.
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So excuse me if I get a few terms wrong or don't really know why and how a 3" system makes such a difference, but this posting may help encourage a few others like me out there who may be considering such an upgrade.
I've read enough postings to know that for a stage II tune, a larger DP and exhaust is required. Not wanting to do software twice, I decided to just get it all done, starting with the pipes.
New IPD downpipe
![Image]()
3" stainless exhaust based upon "R" Kelly's proposed system
http://forums.swedespeed.com/zerothread?id=53646
Components
![Image]()
The first trick was finding a shop that would agree to do the job, work in stainless, use quality welds/bends, and that had more experience than the senior guy at the typical muffler shop. I found two or three that would work in aluminized, and a few who flat out said that the muffler would never fit.
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Finally, I went to check out Diamond Fabrication in Warren, MI. Diamond has been doing custom headers and exhausts for Detroit powered race and drag cars for about 12 years. http://********************/smile/emthup.gif He races them too. I already had all the components and he had the stainless in stock, so we started into it…..
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The only installation set-back was that the upper most downpipe bolt broke off
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in the turbo flange, which I understand is pretty common… (And the number one reason I was not going to do this myself…. Been there, done that
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) This resulted in a few hours of drilling and re-tapping, but he got it done and only toasted about 5 or 6 drill bits.
The rest of the job was straightforward but slow. Diamond was pretty meticulous in his cutting and fitting. We looked at several options of routing to see how the resonator and muffler would appear from the side and rear of the car. We agreed that it would look best with the pipe as horizontal as possible using a small drop just before the Haldex. We decided on two bends rear of the differential to bring the muffler a bit higher and keep it a bit more horizontal than we saw on "R" Kelly's install.
Of course ground clearance was a major concern too. We decided not to put any 'oval' shaping in the pipe below the Haldex for now. The clearance as I measure in my garage is about 3.5" at the lowest point. So far, no problems on the dozen speed bumps and rough railroad crossings I have traveled. The closest fit above the pipe is in the area of the rear sway bar. There is just about enough room for an index finger.
So now the photos…. Thanks to the snow melt and road salt, these are not the best…
In the Spring I think I will paint everything from the DP back in a high-temp flat black, except the tip of course!
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The exhaust note is really cool. (Sorry that I don't have a decent digital camcorder for sound clips, but I spent it all on the R this year!) Sounds like it belongs on the track at high throttle / boost, but I can sneak through stop and go traffic in town without any attention.
I was a bit concerned about the interior resonance at first, but when I unloaded the back of the old exhaust & DP, then put the seats back up, it sounded better. Then, I was really surprised.
![Image]()
…… I reset the ECU and have driven about 120 miles in a 'spirited' manner. The sound has changed a bit and the resonance is so much less.
![Image]()
http://********************/smile/emthup.gif
The increased response of the turbo is certainly noticeable. Next week I will be programming my RICA stage II and I can't wait to feel the difference!
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http://********************/smile/emthup.gif
Thanks http://********************/smile/emthup.gif http://********************/smile/emthup.gif
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to "R" Kelly (and all those who had input his exhaust write-ups), Lucky at IPD, George at VIVA Performance, Phuz, and the entire crew on the R Forum who always seem to have the answers we new owners need.
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Bill
Here is an audio/video mix.... CAUTION High Speed Connection Rqd.
3" Custom Exhaust
EDIT... Too much bandwidth required... Link to video gallery instead..
Hint: Pause each video just as it starts and let the grey line buffer fill to the end, then click play
http://s128.photobucket.com/al...ideos
Excuse the quality as this was taken with a cheap digital camera that captures video. There is a bit of popping interference which is the microphone and not from the car.
Modified by Move Over! at 9:58 PM 1-13-2008
Modified by Move Over! at 1:28 PM 10-29-2008
Updates added on page 2.
ORIGINAL POST
I guess I should start by saying that I have never done, or had done, this type of work before. I don't weld, not exactly sure if I understand what 'off-throttle response' means and half the time I need to ask my neighbor to help me get my kids 2-stroke dirt bike to start.
I've read enough postings to know that for a stage II tune, a larger DP and exhaust is required. Not wanting to do software twice, I decided to just get it all done, starting with the pipes.
New IPD downpipe
3" stainless exhaust based upon "R" Kelly's proposed system
http://forums.swedespeed.com/zerothread?id=53646
Components
The first trick was finding a shop that would agree to do the job, work in stainless, use quality welds/bends, and that had more experience than the senior guy at the typical muffler shop. I found two or three that would work in aluminized, and a few who flat out said that the muffler would never fit.
Finally, I went to check out Diamond Fabrication in Warren, MI. Diamond has been doing custom headers and exhausts for Detroit powered race and drag cars for about 12 years. http://********************/smile/emthup.gif He races them too. I already had all the components and he had the stainless in stock, so we started into it…..
The only installation set-back was that the upper most downpipe bolt broke off
The rest of the job was straightforward but slow. Diamond was pretty meticulous in his cutting and fitting. We looked at several options of routing to see how the resonator and muffler would appear from the side and rear of the car. We agreed that it would look best with the pipe as horizontal as possible using a small drop just before the Haldex. We decided on two bends rear of the differential to bring the muffler a bit higher and keep it a bit more horizontal than we saw on "R" Kelly's install.
Of course ground clearance was a major concern too. We decided not to put any 'oval' shaping in the pipe below the Haldex for now. The clearance as I measure in my garage is about 3.5" at the lowest point. So far, no problems on the dozen speed bumps and rough railroad crossings I have traveled. The closest fit above the pipe is in the area of the rear sway bar. There is just about enough room for an index finger.
So now the photos…. Thanks to the snow melt and road salt, these are not the best…
In the Spring I think I will paint everything from the DP back in a high-temp flat black, except the tip of course!
The exhaust note is really cool. (Sorry that I don't have a decent digital camcorder for sound clips, but I spent it all on the R this year!) Sounds like it belongs on the track at high throttle / boost, but I can sneak through stop and go traffic in town without any attention.
I was a bit concerned about the interior resonance at first, but when I unloaded the back of the old exhaust & DP, then put the seats back up, it sounded better. Then, I was really surprised.
The increased response of the turbo is certainly noticeable. Next week I will be programming my RICA stage II and I can't wait to feel the difference!
Thanks http://********************/smile/emthup.gif http://********************/smile/emthup.gif
Bill
Here is an audio/video mix.... CAUTION High Speed Connection Rqd.
3" Custom Exhaust
EDIT... Too much bandwidth required... Link to video gallery instead..
Hint: Pause each video just as it starts and let the grey line buffer fill to the end, then click play
http://s128.photobucket.com/al...ideos
Excuse the quality as this was taken with a cheap digital camera that captures video. There is a bit of popping interference which is the microphone and not from the car.
Modified by Move Over! at 9:58 PM 1-13-2008
Modified by Move Over! at 1:28 PM 10-29-2008
