Exhaust upgrade

[Ben Savill]

Seeking to draw from the collective wisdom and experience here on the forum. Looking to replace the standard exhaust system with a complete manifold to back box system. Going to ditch the heat exchangers. Current options are either a system from Hayward & Scott or FvD ( buying direct from manufacturer in Germany ). An absolute must is that it needs to comply with noise regs for track days. Has anybody got something similar on their car or can they recommend an alternative. Thanks, Ben.

 

[gxc67]

Have a decat an g pipe system on mine, it's quite loud, about 105db, suggest you need rear box and either cat or other box for track noise regs. Mine is a Dansk, sound is brilliant but very loud!

 

[oldtimer]

Hi Ben , I think you need to have 100db as a target noise level at '3/4 max revs'......but note its getting harder to get away with a 4500rpm figure for '3/4 max revs' these days unless you stick a false 6000rpm red bar on the rev counter. You can blame the GT3s for this as being the commonest Porsche911 on trackdays now , and revving to 8000rpm+ max which has the testers thinking we can all rev high. The 100db is a tough target for 964s . With standard exhaust and 4500 you will be OK - just. With decat and cup pipe ( primary silencer bypass ) and standard secondary you will be making 107db at 4500. With decat and standard primary and standard secondary you will be making 101 db at 4500 and 102-3 at 5000. I have ended up with this latter configuration so when at Combe or Bedford or an (evening) Brands session I am making sure I have hot engine and clutch disengaged and rocksteady right foot to make 100db. Assuming you are ditching the standard exhaust system and you want to (a) lose as much weight as possible and (b) to maximise volumetric throughput so that power losses are restricted and (c) at least get onto 105 days , then go for decat + cup pipe + Will Norman tip ( the one with the removable extra muffler , not cheap )..... Chris Whittle has something like this and he makes 103db from memory on the 964RS Clubsport ....

 

[Ben Savill]

Hi O/T. Thanks for detailed reply. This exhaust thing has all come about thanks to the engine rebuild. One of the original heat exchangers is totally shagged at the flange, having been welded and re-welded there is nothing left to bolt up. Given the cost of a replacement heat exchanger, I thought I'd investigate other options. Having looked at Fabspeed and Hayward & Scott, I've gone for one made by M&M in Germany. They make complete systems for many cup car race teams as well as Porsches used in all sorts of other disciplines. They are also the manufacturer for the FvD system. Noise will be between 98-100Db's, no heat exchangers, equal length manifolds, single outlet etc etc. Definitely worth contacting M&M directly as it is significantly cheaper than going through FvD. Will post some pictures and thoughts when it is all fitted up. Cheers Edited because I am a dumb a** with a bad case of man flu and put the wrong name of the exhaust manufacturer in!

 

[iangray100]

Ben, Have you got DnD web address as Goggle is not coming up with it ? thanks

 

[Steve Brookes]

ORIGINAL: Ben Savill Thanks for detailed reply. This exhaust thing has all come about thanks to the engine rebuild. One of the original heat exchangers is totally shagged at the flange, having been welded and re-welded there is nothing left to bolt up. Given the cost of a replacement heat exchanger, I thought I'd investigate other options. Cheers

Ben, this is affecting more and more of us. As you say new H/E is horrendous cost (£2000+ when I checked). I had the old flange cut off and a new one welded on. Saw another having the same job done last week. Cost is between £200-£300.

 

[Ben Savill]

Ian, Absolutely right. That's because I put the wrong name in!! Can only blame it upon my man flu and lack of sleep. Name now corrected within original post to M&M. Here is the link: http://www.m-m-germany.de/ENG/index.php

ORIGINAL: iangray100 Ben, Have you got DnD web address as Goggle is not coming up with it ? thanks

 

[Ben Savill]

Exactly Steve. M&M system without heat, inc VAT and delivery is approx EUR3,000. I don't need / want the heat so the system is a little cheaper, otherwise looking at about EUR3,500 from memory.

ORIGINAL: Steve Brookes

ORIGINAL: Ben Savill Thanks for detailed reply. This exhaust thing has all come about thanks to the engine rebuild. One of the original heat exchangers is totally shagged at the flange, having been welded and re-welded there is nothing left to bolt up. Given the cost of a replacement heat exchanger, I thought I'd investigate other options. Cheers

Ben, this is affecting more and more of us. As you say new H/E is horrendous cost (£2000+ when I checked). I had the old flange cut off and a new one welded on. Saw another having the same job done last week. Cost is between £200-£300.

 

[Steve Brookes]

Looks a cracking system Ben....please take some pics and let us know your thoughts when it's on. [] edited for spelling!

 

[NeilW]

Ben, the heat exchanger flange is fairly rotten on mine also. Coupled with an occasional smell of exhaust fumes in the cabin I looked at replacing both manifolds. As you've discovered they are mucho £. I found a pair on e-bay, located in California, and bought them with a delivered cost of £350. They are in absolutely superb condition, just shows how well they can last in a drier climate. I search e-bay daily for several weeks before finding a pair, but thought I'd mention it as another option. Good luck.

 

[ras62]

Looks like a great system. I would imagine the 2 cats add considerably to the cost but there is an option to delete these if I understand the info on the site.

 

[Ben Savill]

Agreed Ras - price I was quoted and then relayed on this thread included the cats. You can - and I will be - deleting the cats. Not sure what that does to the price as yet, but if all the other systems are anything to go by, the savings from deleting the cats should be quite significant. Will post more details as and when I have them. Need to get the motor back together first!

ORIGINAL: ras62 Looks like a great system. I would imagine the 2 cats add considerably to the cost but there is an option to delete these if I understand the info on the site.

 

[Ben Savill]

You did exceptionally well there Neil. I bought a complete intake system from the States for decent money just recently as I was struggling to find the plastic inlet manifolds in the UK. It's always a leap of faith but happy to not be let down.

ORIGINAL: NeilW I found a pair on e-bay, located in California, and bought them with a delivered cost of £350. They are in absolutely superb condition, just shows how well they can last in a drier climate.

 

[ras62]

Good choice Ben, certainly the way I would go. I wonder how much more it would cost to have the rear box in titanium? Maybe worth a double check on the dB produced with the cats deleted. Look forward to some pictures Cheers. Rob