DesignTek Exhaust muffler bypass X pipe

[angusc]

Yes ditto, ditto......... I started removing my cats and headers two days ago. My cat bolts were almost non existent and the nuts had corroded to points of steel. I used a hammer and large punch to hit the bolt ends and this luckily allowed them to release the remaining corroded nuts. I removed the CAT pipes complete with oxygen sensors firmly seized in place. The header bolts were a major concern, as new the bolt heads are 13mm AF only a few of the total 12 bolts still had 13mm AF and others were 12mm and incredibly down to 10mm on one! I used a six sided socket set and was able to release all bolts without any shearing off....phew!

The chrome header pipes went on yesterday but I had to ordered a replacement tandem pump as the original was also badly corroded and needs replacing before the X-Pipe gets fitted.

The oxygen sensors are proving a challenge to get out from the original cat pipes. Today I managed to heat up the socket nuts and removed two of the sensors from the right hand side pipe, but the nearside pipe is more challenging. I will tackle that one tomorrow.

Hopefully tomorrow my new tandem pump arrives at OPC and I can crack on.

 

[raykelly]

You're going to have to take pics and shows us the final product when complete! It will look great but will sound even better! even a video of the sound would be good!

Oh the header bolts :-( I would be very afraid of those! I've been spraying wd40 on mine every chance I get, the past few months. Just in case I decide to follow you on replacing the cats! Great you got them off! Crazy how bad they can get!! Down to size 10mm!

I've seen these Oxygen sensors... was hoping that they would be easy to get off! (Ive also been spraying wd40 on them lol) Is it easier to replace them?

You're almost finished! Im sure you will be delighted with the job!

The worst part is now over. Keep us posted!

 

[raykelly]

Hi what headers and all did you go for? Fabspeed?

 

[angusc]

Well the actual header bolts threaded section were all very good condition, only the bolt heads had corroded down a lot. You definitely need the six sided impact sockets and just hammer them on to the bolt heads. I will post pictures once I get a chance.

I purchased the headers and X-Pipe from design911.com they had to manufacture the parts but delivery was within 3 weeks. Excellent quality parts and finish, which you will see when I upload photos.

 

[angusc]

Well the actual header bolts threaded section were all very good condition, only the bolt heads had corroded down a lot. You definitely need the six sided impact sockets and just hammer them on to the bolt heads. I will post pictures once I get a chance.

I purchased the headers and X-Pipe from design911.com they had to manufacture the parts but delivery was within 3 weeks. Excellent quality parts and finish, which you will see when I upload photos.

 

[raykelly]

Design911.com, I was checking them last night to see what they offered but couldn't see any headers. Very good to know that they would manufacture them. I was looking at Fabspeeds and they are over £2K. I was reading that if you replaced the headers, intake, intake pendulum, and used an X-pipe..... you would have around 50bhp increase and similar torque gains! Never thought you would get this amount. Then if you were to buy their tuner, you could possibly get better. One of the reviews I read stated they got 14bhp from the intake, then they added the x-pipe and got another 5bhp!

Looking forward to the pictures! Good luck with the finishing touches.

 

[angusc]

Here is the link for my 997.1 parts just change to your vehicle model.

http://www.design911.co.uk/fu/prod127041/DesignTek-Sports-Exhaust-Package--and27-to-30-bhp--Porsche-997-C2---C4---C4S/

Tonight I got the tandem pump and X-Pipe installed and now looking to change the spark plugs tomorrow while I have the rear bumper off.

 

[raykelly]

Neat bit of kit! can't wait to hear your feedback once all is fitted! It's going to be fantastic!

 

[angusc]

Tonight I finished the exhaust install and checking my spark plugs. Fired up the car and pressed to say that the oxygen sensors are all still working ok, nice smooth idle! No exhaust leaks...... I could hear a rattling sound from the right hand side but it turned out to be a cracked exhaust bracket on the tail pipe trim that has probably been like that for ages. I will get it welded up tomorrow and then re-fit the rear bumper.

I will attempt to upload photos now but not sure anymore how to easily do that as photo bucket ha now made their mobile app "better" and it don't work anymore like it used to!

And we all know how easy it is to upload to the PCGB forum

Ok let see if this link gets you to the photos, as this forum does not allow uploading of photos directly it is not easy (possible) to order the photos and add comments, like on every other forum that I subscribe to.....

Porsche 997.1 Exhaust Upgrade http://s1113.photobucket....how/Exhaust%20Upgrades

 

[raykelly]

Great! Im waiting

Happy Days!

Uploading photos is a pain.... it does seem to allow you to select photos directly from your PC and upload them. Not sure if that was always there or its new. Though it doesn't seem to appear all the time. Ahh I know now. Don't do a 'quick reply' option in Thread. Use the 'Open full version' option (located just above the 'B' for bold option in the quick reply section) then the attach photos icon appears on the right hand side. If that makes sense.

 

[angusc]

Great! Im waiting

Happy Days!

Uploading photos is a pain.... it does seem to allow you to select photos directly from your PC and upload them. Not sure if that was always there or its new. Though it doesn't seem to appear all the time. Ahh I know now. Don't do a 'quick reply' option in Thread. Use the 'Open full version' option (located just above the 'B' for bold option in the quick reply section) then the attach photos icon appears on the right hand side. If that makes sense.

Yes but for those of us not tied to a PC and using only a mobile phone it it's useless....nevermind no point complaining.

 

[angusc]

Since undertaking this project there are definitely things that I would recommend others to think about. The inexcusable use of steel bolts and clamps by Porsche has introduced some concerns about galvanic corrosion of these parts and if left unattended will end in tears. If you have an older Porsche probably more than 5 years old then you really should think about asking the OPC to do the following at your next service:

Change out all exhaust manifold bolts.

Change out all exhaust clamping bolts.

Change out all muffler mounting bracket bolts.

Insist they use a copper slip lubricant on steel fixings.

Remove and replace the engine earth lead fixing to the chassis and apply list of copper slip to maintain the electrical conductance.

If your car is 10 years or more, then on top of the above:

Replace your tandem pump and apply copper slip to the pump casing to prevent later corrosion to the housing.

 

[raykelly]

Yes but for those of us not tied to a PC and using only a mobile phone it it's useless....nevermind no point complaining.

Ha I was thinking that when I was writing it ;-)

 

[raykelly]

Yep I can second your advice there about all those bolts!

Ive gone through the pain myself but hope now I will never have to again...

The tandem pump, where is that located?

 

[angusc]

Rear right hand side as you look at the back of the engine. Just behind the exhaust header flange connection.

 

[raykelly]

Thanks for that. Will have a look for it.

 

[Ianstewartshouse1]

https://flic.kr/p/VqmtXB

There red is the position on 997.2 engine in green if it works!

part number is

porsche 9A1-110-090-06 Vacuum Pump I think!

ian

 

[raykelly]

Yep got it. I don't need one but just wondering where it was

Cheers!

 

[angusc]

Well I got to take the babe out on Wednesday for a nice long run after the X-Pipe and headers were installed and the rear bumper re-installed. I'm very please with the sound of the headers and X-Pipe, it is not louder at all with the PSE closed and sounds very similar to the original stock sound on idle. when revving the engine at stand still there is a noticeable throatiness that is very pleasing without being loud or obnoxious. But as before I definitely prefer the sound with the PSE open, again I wouldn't say it was either excessively loud or annoying to others but gives the deeper throaty sound that such sports cars should have. Other than that there are no other apparent changes to the driving or handling and the driver satisfaction smile is as big as every

All in all i spent around 2K on the headers, X-Pipe, Tandem Pump, gaskets and accessories, not that I was counting so might have been more, definitely not less. Got a great feeling of making real improvements to the car by replacing all those horrible studs and exhaust brackets and of course the Tandem pump. I replaced the exhausts studs with standard Porsche parts so it will also be on my two yearly maintenance plan to replace these to prevent future corrosion issues.

Sorry I did not have chance to do any sound recording and now away at work for a while. But trust me as I was advised by others here that have also fitted the X-pipe if its something that you felt you want to do then you wont be sorry. For those of you that like stock only then its obviously not for you.