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      04-15-2014, 11:40 AM   #1
Steeler
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Non M custom exhaust project

Hi Guys,

Firstly thanks to Josh(pokeybritches) for his willingness to answer many questions at the beginning of this project

As there is next to nothing as far as complete hi flow exhaust systems front to back for the 3.0i, I wanted more flow to let the VF Engineering blower do its thing as well as to be able to add more boost down the road, so I made it my winter mission to fabricate a system from readily availible materials that I am fortunate to work with daily.
I used 2-1/2" diameter .060" SS 304 tubing and sanitary fittings typically used in the brewing and water treatment industry.
I bought 400 cell hi flow cats and a muffler from Magnaflow also adding an x-pipe and AC Schnitzer tips and got to work.
The headers are from Bimmerbrakes and were designed for the BMW E46 chassis but fit perfectly and would actually have bolted up directly to existing piping once the log manifolds were removed.
The coating is by Fireball Coatings in Erin Ontario. Mark is the owner, a great guy to deal with.
His company has developed an internal coating through development with the University of Waterloo that further retains heat inside the header by 25% in addition to the already 45% retention of the outer coating over bare metal while gaining an 8% increase in air flow.
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W2A Intercooled Vortech V3Si, custom ducting, Alpha N, 60# Bosch,2.62 pulley, multi port WMI, Severn Tuning(pokeybritches), Tial, magnaflow,SS race muffler, 42 design,3.91LSD, H&R, Hotchkis,ST coils,Konis, Megan camber arms, AKG SS, Nylon mounts, Poly bushings, Carbon interior, CF Aero.APEX

Last edited by Steeler; 01-06-2015 at 05:04 PM..
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      04-15-2014, 12:16 PM   #2
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Nice work!
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      04-16-2014, 03:06 PM   #3
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Great work! Love the custom project. Can't wait for sound clips!
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      04-18-2014, 12:48 PM   #4
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Thanks for the comments guys
Sound bytes to come
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W2A Intercooled Vortech V3Si, custom ducting, Alpha N, 60# Bosch,2.62 pulley, multi port WMI, Severn Tuning(pokeybritches), Tial, magnaflow,SS race muffler, 42 design,3.91LSD, H&R, Hotchkis,ST coils,Konis, Megan camber arms, AKG SS, Nylon mounts, Poly bushings, Carbon interior, CF Aero.APEX
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      04-18-2014, 01:43 PM   #5
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Excellent work!
Did you do your own welding? Looks great.
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      04-18-2014, 05:59 PM   #6
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Thanks Ian , yes fit and welded by myself.
Got it all fitted on the car today, just need to run the O2 wires and torque down the header stud nuts and I can fire her up.
Sunday looks like a good day for a shake down run.
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W2A Intercooled Vortech V3Si, custom ducting, Alpha N, 60# Bosch,2.62 pulley, multi port WMI, Severn Tuning(pokeybritches), Tial, magnaflow,SS race muffler, 42 design,3.91LSD, H&R, Hotchkis,ST coils,Konis, Megan camber arms, AKG SS, Nylon mounts, Poly bushings, Carbon interior, CF Aero.APEX
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      04-20-2014, 10:25 AM   #7
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OK here is the sound clip of my exhaust project
I have got the system bolted directly to the car in 3 spots. I do have sandwich mounts that I can install but will drop the system by 3/4"
Let me know your thoughts on the sound
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W2A Intercooled Vortech V3Si, custom ducting, Alpha N, 60# Bosch,2.62 pulley, multi port WMI, Severn Tuning(pokeybritches), Tial, magnaflow,SS race muffler, 42 design,3.91LSD, H&R, Hotchkis,ST coils,Konis, Megan camber arms, AKG SS, Nylon mounts, Poly bushings, Carbon interior, CF Aero.APEX

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      04-20-2014, 11:05 AM   #8
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Dave,

The solid mounting may have something to do with it, but the first place I would look is the muffler. It has the greatest impact on sound. Does Magnaflow offer quieter options?

Another option is to weld in resonators to clean up the sound a bit. It may be tricky considering the exhaust is ceramic coated. Hope this helps.
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      04-20-2014, 12:19 PM   #9
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Dinan is known for being on the quiter end while still having better tonal qualities than the stock muffler.

www.dinancars.com

There's also Remus, Eisenmann (sport), and Arqray.
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      04-20-2014, 02:01 PM   #10
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Thanks Josh.
I have a few leaks at the flanged connections and I will put the isolators in and see how I like it

How does it sound to you.?
The recording is fairly close to real life
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W2A Intercooled Vortech V3Si, custom ducting, Alpha N, 60# Bosch,2.62 pulley, multi port WMI, Severn Tuning(pokeybritches), Tial, magnaflow,SS race muffler, 42 design,3.91LSD, H&R, Hotchkis,ST coils,Konis, Megan camber arms, AKG SS, Nylon mounts, Poly bushings, Carbon interior, CF Aero.APEX

Last edited by Steeler; 04-22-2014 at 11:09 AM..
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      04-21-2014, 07:39 PM   #11
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It sounds different than mine. I think your muffler has a lot to do with it.

Mine is quiet except under load. I don't know if I would call what my exhaust emits "rasp"... because it's entirely different from the buzzy/tinny sound coming from some S54's. It sounds smooth except at WOT, where it sounds mildly distorted, but in a mean rally car kind of way.

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      04-21-2014, 07:44 PM   #12
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Now with the cats installed. The exhaust sounds a little cleaner/refined and less fiery.

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