Exhaust. My biggest failure.
 

Building my car whatever I did had to meet at least one of these 3 simple rules:
1: improve function and/or
2: save weight and/or
3: encourage me to want to drive more.

My biggest failing and regret was the exhaust. And it was all my fault.

Seduced by weight savings I went for a full titanium single exit 2.75” system, from the over pipe back, off the shelf from a reputable aftermarket manufacturer. (the engine has a Harrop supercharger fitted)
There were certainly weight savings, around 20kg, and the construction was very good, with gorgeous looking welds.

But, from the start, is sounded awful…raspy, annoying, lightweight…. no depth at all. And loud. Way, way too loud.

So I find a genuine old school exhaust guy. Great guy, has worked with all the Australian racing greats, there is a genuine 427 SC Cobra sitting on one hoist, a Matich Can-Am car sits on a trailer…he has just finished a Jaguar XJ220. A proper greasy, fully filled with stuff, workshop.

Low key and down to earth, happy to see how he can quieten down my car.
He asks why I went off the shelf titanium… in fact then asks why I went titanium at all. Smiles, says nothing.

Decides the only way to reduce volume is to construct his own large rear muffler, explains that the only real way to contain “volume” is by increasing, maximising the volume of the main muffler.

So we remove the new titanium one, and a week later I pick the car up with a very large, but tucked up, 321 stainless muffler, completely hand made by him.

Car sounds better, much better, and nowhere as loud. But still not great, still a little raspy a little bit still annoying.

He smiles again, I decide I can live with it for a bit longer…I might get used to it.

A year later, Ive already been back twice with fractured titanium welds (it gets a lot of use on dirt and back roads). He explains titanium can only be repaired a limited number of times…and for continued rough/hard use, it will keep on cracking and fracturing, especially since they are not exactly tucked up under the car to any great extent. And it will continue to not sound so flash.

So I bite the bullet, “what should I have done from square one?”.
Don’t get seduced by flashy adverts for Titanium exhausts, I should have found a bloke like this, asked him what to do, and how to do it…. and paid him to do it.
So I did that….
The new system was about %50 more expensive than the titanium system, hand made in a light(ish) gauge 321 stainless, about 10kg heavier than the titanium system.
It is fully tucked up, pretty much in line with the floor, the only compromise being that impossible to avoid rear subframe crossmember.
It sounds wonderful, deeper, richer. (In fact at rally days I keep getting Subaru guys coming up asking why it sounds so good).
Its strong, solid, hasn’t had any issues now for a number of hard years.
And importantly… it flows perfectly.

The moral of this long winded story is that there is proper old school type knowledge, wisdom and amazing expertise out there that can save you time, money and grief.

And the answer to many of your current exhaust questions (in fact most car questions) is not to be found in flashy internet claims or adverts…. but in real workshops, with real mechanics and constructors, all around the world.
(pics below are of the latest system....very happy with it)

Thanks for sharing this! Our engines just don't sound good, so it definitely is a challenge.

Good to check beforehand what the sound would be like with any new exhaust component you're putting on. Happy you ended up where you liked it though. And hopefully you kept a few people from making the same mistake.

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The front pipe is where most of the drone in the cabin comes from usually with a full exhaust. You could try going back to stock (minimal losses unless you are pushing a ton of air), or put in a large resonator or 2 to try to reduce the drone.


Something like this Apexi Front Pipe has. https://frsport.com/images/detailed_...-t014j_1_1.jpg

OR ...... just have put an aftermarket axle back muffler on it and called it good - :thumbsup:

yeah cheers, all good now with the new custom system above, zero drone, and sounding deep and perfect... and with the supercharger it needs the extra capacity. :)

Girthy looking. Is that one still 2.75" or larger?

You're not the first to have an expensive mod not work out. Glad it worked out in the end. Live and learn.

yeah its still 2.75" , it does look bigger, but maybe its a bit distorted by the lens. :)

Ti is hard to work with and requires a bit of post processing treatment. There are issues with contamination during welding and machining that you have to be extra careful with. Without it I wouldn't doubt it fatigues and fails pretty easily. Repairing it would exaggerate the issue even further, the heat effected area would be under stress and it would fail even sooner due to the residual stress and possible additional contamination from welding.

I particularly enjoy the shield he put in front of the resonator.

I feel you. My corsa catback with Tomei UEL header and overpipe is right on the edge of acceptable. It has grown on me a lot, but I intentionally left stock frontpipe with the cat so my ears wouldn't be bleeding.

I really hope you figure it out. Too loud of a car really takes the fun out of them. About 8 years ago I had a MR2 with only a front pipe and it was embarassing...

Bingo! You quickly (and easily) spotted one of the key reasons why an older experienced head is so valuable in car world.

It was one of those pleasant surprises when I picked up the car... I hadn't asked for it, and I wasn't even smart enough to think to have come up with the idea!

Exactly why paying more, and allowing time, for some things from (some) people is actually a wise investment.

Thanks mate, but its pretty much %100 perfect now with the system he made for me, so very very happy :)

So what does it do considering the joint is just in front of it?