Going fully custom catless exhaust: Clear goals, yet so many questions!

[Crusard]

Hey all! I'm looking into getting a new exhaust system, with these things in mind:

• Best power gain for buck
• Should have a more distinctive sound
• Should be bearable: Not a daily driver car, but the sound should be tolerable

I live in Argentina, so a branded design is not a viable option. I'm going fully custom made with a welder who seems to know what he is doing (his instagram here) and his team, which includes a guy who will custom-tune it after the hardware is made.

It'll be completely catless. I think I'll go with UEL header for the distinctive sound. I'm aware it yields slightly less top HP, but I believe it's worth it.

Regarding sound, this is a major concern for me. I've heard opinions saying the UEL rumble is more bearable than EL (such as seen here youtu.be/BulaOy5dHYQ), however removing both cats is definitely noisy, and I'd like to keep it civil "enough" for the occasional trip.

I'm still considering different pipe diameters. I've read going more than 2,5" on a NA exhaust is not superior than 3" (theretically, because of uneven airflow), but there's also some documentation stating the opposite, or at least small gains.

So with this in mind:

1. Do you have any recommendations regarding resonators?
2. Which tube diameter should I go for?
3. Which UEL header build (piping, etc) seems to work the best?
4. Any other recommendations or considerations I should relay to the workshop team? (this is the first time they'll be working on an 86)

[Joveen]

I would recommend getting resonators to get a good sound from the catless front pipe. And maybe a resonated exhaust with high flow mufflers.

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[mav1178]

How is a branded exhaust not a viable option? You can get Ace or something else shipped to you via DHL internationally.

[86MLR]

Punch cat in oem header, 2.5" header back exhaust, dual resonator front pipe, throw a small muffler on the rear and away you go.

[Crusard]

Originally Posted by mav1178

How is a branded exhaust not a viable option? You can get Ace or something else shipped to you via DHL internationally.

Full exhaust replacement + custom tune, all done locally = They're charging me +/- 1350 USD

If i wanted to import the ACE header alone (it's 1700 USD, on sale), I get another 800 USD shipping, plus +50% of that in import taxes. So getting the header alone is around 4200 USD, plus yet another +30% argentinian peso-to-dollar trade tax. So getting a branded header in argentina, equals getting a top tier bolt on turbo kit on the US. It's just that messed up.

[mav1178]

Originally Posted by Crusard

Full exhaust replacement + custom tune, all done locally = They're charging me +/- 1350 USD

If i wanted to import the ACE header alone (it's 1700 USD, on sale), I get another 800 USD shipping, plus +50% of that in import taxes. So getting the header alone is around 4200 USD, plus yet another +30% argentinian peso-to-dollar trade tax. So getting a branded header in argentina, equals getting a top tier bolt on turbo kit on the US. It's just that messed up.

https://aceheader.com/TYPE-A-GT86-FR...LHD-p133843679

It's $95 USD to ship worldwide (from Taiwan), not sure where you got the $800 USD shipping charge from unless you're solely quoting from a US vendor.

I understand if you're looking for something cost-effective but you wrote "not a viable option" which initially suggests you have a legal restriction preventing you to import an exhaust system into Argentina.

[Crusard]

Originally Posted by mav1178

https://aceheader.com/TYPE-A-GT86-FR...LHD-p133843679

It's $95 USD to ship worldwide (from Taiwan), not sure where you got the $800 USD shipping charge from unless you're solely quoting from a US vendor.

I understand if you're looking for something cost-effective but you wrote "not a viable option" which initially suggests you have a legal restriction preventing you to import an exhaust system into Argentina.

I've never seen a shipping cost that low for the size and weight. But even if it was that cheap, it would mean 3500 USD just for the header. And the full (header, fp, catback, etc) custom exhaust + custom tune, is 1350 USD done locally. That's why I'm looking for design advice.

[mav1178]

Originally Posted by Crusard

I've never seen a shipping cost that low for the size and weight.

It's because at full retail price, the margins on the exhaust direct from the factory can subsidize cheap shipping costs.

[86TOYO2k17]

Have a shop cut out both your cats and weld in resonators in there place. That would be best bang for buck while keeping sound tolerable. Then get a custom tune. Add E85 if you have access to it. Add a layer of sound deadening to your spare wheel cover/trunk liner, goes a long way keeping cabin volume down.