RESEARCH Exhaust System

[Diokaef]

New pictures on page 25, 26, 27 and 28...

Almost there!!!

New Exhaust system for Z4M SC and NA

see post #945 and #956 for more info

Originally Posted by Diokaef

Guys here is a simple explanation of the exhaust theory that I used to create this system.

S-Pipe

The S-Pipe is basically designed to work as an extension of the headers, while optimizing flow and velocity with the least amount of constriction. The coating and step are both used to achieve this process. The tabs are used to bridge resonance which reduces unwanted rasp.

X Pipe

The X-Pipe uses the same principle as the S-Pipe for performance, with the addition of minimized bends to diminish constriction. The crossover area’s main purpose is sound equalization. (The S54 engine doesn’t benefit from crossover scavenging in it’s current location).

Bypass Area

Resonators
Street V1 is used to optimize the sound while Street V2, Sport V1 and V2 are used to achieve a balance between sound and performance.

Straight Pipe
Race V1 and V2 are used strictly for performance applications or when extreme annoyance to neighbors is desired.

Cats

CTS 300 is used in the attempt to relocate secondary O2 sensors without causing a CEL.
CTL 100 is used to maximize performance when a catalytic converter is required.

Also is good to mention that this system was designed to achieve its maximum capacity using open flow headers.

[ZStig]

#1 concern for me would be drone.

[Dammmittt]

What kind of engineer are you?

[mfanatic325]

I'd be interested in CA smog-legal system for my Z4MC ~$800 price range. Some nice titanium-burnt tips and an appealing design overall would be sweet
Don't really care for much power gain, as long as there's for sure no power loss =P
And yes, sound is important. I don't personally like rasp, nor drone. A nice deeper growl over stock would be cool.

[Diokaef]

We are concerned about power first, and having in mind the Ess Superchargers, it will be designed to comply and increase power from the 3 stages Ess superchargers.

Our design will use similar technology of AA IV Headers, SuperSprint Section 1 and 2.

the sound will be measured and we will have two options

No Catalytic converters (will be sold as add on)

The exhaust will become Headers, Section 1 divided by two, and section 2 divided by two.

The design is based in exhaust speed.

Will be a 3 company partnership.

It will be Dyno tested with engine out of the car and with engine in the car,

It will be Ceramic coated.



So will not be a cheap fix.

I had contacted Roman from Ess to acquire data necessary for the design since they have plenty of experience with our engines and they also build the superchargers.

It's not a back yard exhaust, we will put this on the market if the interest is there and will be a small production scale

[Diokaef]

Originally Posted by Dammmittt

What kind of engineer are you?

Mechanical.

[JB 007]

Originally Posted by Diokaef

How much extra power would you be interested from a full exhaust system
(Headers, Section 1, Section 2 and Mufflers)?


How much would be a reasonable price?

How important the possibility of a DIY swap connection to be able to pass emissions for you?

Minimum 35bhp..

$1200

I have no idea...

[Diokaef]

35+ is what we have in vision.

Price not so much.

AA headers goes for around 1800$
SS section 1 699$
SS section 2 760$
Ceramic coating all this +- 1000$
Resonators (2) 190$
Mufflers +- 900$
Labor 600$

if take this as real final numbers Almost 6K for the hole system.

Each prototype will be build for different applications.

[JB 007]

Originally Posted by Diokaef

35+ is what we have in vision.

Price not so much.

AA headers goes for around 1800$
SS section 1 699$
SS section 2 760$
Ceramic coating all this +- 1000$
Resonators (2) 190$
Mufflers +- 900$
Labor 600$

if take this as real final numbers Almost 6K for the hole system.

Each prototype will be build for different applications.

first one will be for stage 2 supercharger and may be of equal value for stage 1, but definitely not for stage 3 or naturally aspirated. We will work on does later.

$1200 without manifold..

$900 for manifold are reasonable I think..

[mfanatic325]

omg...significantly over $1k is out of my budget =[

[Diokaef]

For people with headers w/o cats we will be able to add it to the system
for people with SS sections we will be able to modify to work with our system.

So you would only pay for the Labor and coating plus the extra parts of the exhaust.

[ScottinSSMD]

You've just priced your product right out of the market. If you are looking for, basically a straight pipe setup, with thise gains, you will also need to get involved with tuning. Everyone else's systems for our cars are bolt-ons so I am not sure the reason for this mega investment for such a very small market niche. Strictly speaking of the Z4MC you have noted as your target market.

[Diokaef]

Originally Posted by ScottinSSMD

You've just priced your product right out of the market. If you are looking for, basically a straight pipe setup, with thise gains, you will also need to get involved with tuning. Everyone else's systems for our cars are bolt-ons so I am not sure the reason for this mega investment for such a very small market niche. Strictly speaking of the Z4MC you have noted as your target market.

I will be tuning with ESS supercharger installed on mine and also send a prototype to ESS to work with and custom tune. The price above was only for comparison purpose, our price will be much better then that. Z4M is not the only market we will be exploring, The system will be bolt-ons and will interchange with OEM sections.

I love to create new things and I love performance so why not?

The cost will not be extravagant since it will be a partnership project from 3-4 companies that already deal with Racing exhausts.

Also our system will provide you with an option to run straight without cats or with cats for emissions purpose. DIY type swap 10 mins to do it.

[Diokaef]

Feeler $4K for headers, middle section, X-pipe and muffler.

All ceramic coated and dyno tested, tuned.

35+ BWHP


???????????????????

Would you be interested?

[ScottinSSMD]

Seems reasonable. At the end of the day, like many here, we want to hear it first. Get the prototype up and a HDTX sound bite then you could sell us on it. Good luck with your venture.

[Diokaef]

I should have 1st prototypes tested by 1 week of October.

2nd prototype by january, we plan on building at list 3 different types so to optimize gains.

[ZStig]

Originally Posted by Diokaef

Feeler $4K for headers, middle section, X-pipe and muffler.

All ceramic coated and dyno tested, tuned.

35+ BWHP


???????????????????

Would you be interested?

nope. I'm with ScottinSSMD. You're better off offering the kit in sections. Unless it sounds just amazing and doesn't drone when used all together

[mfanatic325]

I still think it's too expensive. I hope it's not because I'm cheapo-minded =/
I mean...I do have a Volk stable, so I can't be THAT cheap, right?

But yeah...I don't think I'd spend much more than $1k for an exhaust. But then again, I'm thinking more along the lines of catback only. As I don't want to have to deal with CA state ref, etc.

[ScottinSSMD]

Originally Posted by mfanatic325

But yeah...I don't think I'd spend much more than $1k for an exhaust. But then again, I'm thinking more along the lines of catback only. As I don't want to have to deal with CA state ref, etc.

Well, that's the other point here. How many really go to one vendor for the complete setup of headers, mids, catback/muffler? Both times I swapped on my Cobra, none of the parts were single vendor based. Always a X header, Y midpipe, and Z muffler, etc. You've really got to have an exceptional product if you think everyone will buy all of your components.

[Diokaef]

They will sell in sections I would not sell only as a set, but again the better price and the hp gains can only be warranted with the complete system the sections will work fine with the stock Parts/section ex. headers, etc...

About the emissions:

People will be able to buy a middle section with exchangeable Cat/resonator.

[Diokaef]

Originally Posted by ScottinSSMD

Well, that's the other point here. How many really go to one vendor for the complete setup of headers, mids, catback/muffler? Both times I swapped on my Cobra, none of the parts were single vendor based. Always a X header, Y midpipe, and Z muffler, etc. You've really got to have an exceptional product if you think everyone will buy all of your components.

It will be the best in the market (Limited production probably only 20 will be available as complete setup and is not for everyone).

Me telling people This or That does not matter, I will bring the Dyno tests to support the product also 3 luck guys will get the system at cost price to test it.

So keep coming, I'm really curious about peoples opinion.

[mfanatic325]

OOHH, okay, then I call dibs for at least a chance @ the 3 lucky test-fit (at-cost) opportunity

Cuz that's probably the only way I can convince myself to pay/afford that much for an exhaust setup =P