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Thread: Pictures of cut open 981 exhaust?

  1. #41
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    Re: Pictures of cut open 981 exhaust?

    Quote Originally Posted by neilvosko View Post
    hey will, this is an awesome post, thanks. much appreciated.

    i would be curious how the sound compares with PSE (the obvious) as well as the Carnewal GT Exhaust Mod
    https://cantrellmotorsport.com/produ...ayman-boxster/

    i wonder if you are essentially replicating the Carnewal GT Exhaust Mod ????
    I honestly don't know, since I have now seen one of those open. My own pictures (so far) are the only ones showing the 981 muffler from the inside that I can find.


    Quote Originally Posted by neilvosko View Post
    my other question is: i wonder if cutting out the whole 90 degree bend section coming out of the headers will increase the exhaust volume ?

    is this what the Carnewal GT Exhaust Mod accomplishes ?
    By fluid theory, the hole I made is so large that the majority of the gases will come out there (less resistance), instead of following the more restrictive bend that follows. I don't think it will make a huge difference.
    2014 Boxster S, DIY Exhaust Mod

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  3. #42
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    Re: Pictures of cut open 981 exhaust?

    OK, I haven't been totally idle, just really busy with family and kid stuff. But time to post on the muffler tip mod .....

    The more I thought about it, cutting and welding was too much work, and would make it harder to do as I would like to. So instead I thought: how about an insert that directs gasses to the two tips instead?
    So I started by measuring the internal diameter of the main tube:



    And ordered a cheap cut-off piece of 6061 Aluminum from Ebay (about $18) which arrived a week or so later:



    I then turned that down in my lathe and verified it was an easy fit in the muffler tip:





    Cut to length (allow room for the clamps to work):



    Once I centered the piece, I used a marker to note the two hole positions:






    I then added cut lines, and "curved" lines (more on these soon):






    Cut along the cut lines:






    Almost finished piece:





    Now, that roughly 45 degree cut is OK, but I wanted a more curved surface (for better flow), so I cut a lot of the excess on the mill, and finished by hand on a bench belt grinder:







    Almost done, but the piece still felt a little "heavy", so I took more material on the mill:








    Now all I have to do is to drill two holes and use metal screws to keep the piece in place (and prevent from it rotating):



    Not "pretty", but it should work really well in separating the muffler gases to each respective tip.

    I finished that piece a couple of weeks ago, so I am now trying to find a quiet morning to do the swap on my '14 Boxster S. I will report back once I do

    Will
    2014 Boxster S, DIY Exhaust Mod

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    Re: Pictures of cut open 981 exhaust?

    Nice bit of "lateral" thinking!
    Bitsobrits
    2015 Base Cayman 6spd-Agate Grey/Black-Sport Plus seats-PASM, PSE, PDLS
    Also in the garage: '63 Lotus Elan, '65 Jag E type FHC

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  6. #44
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    Re: Pictures of cut open 981 exhaust?

    Quote Originally Posted by wquiles View Post
    Not "pretty", but it should work really well in separating the muffler gases to each respective tip.
    Isn't that piece just going to prevent left and right banks balancing the sound, like an H-pipe on a dual exhaust? Was that your goal? It shouldn't make the sound any louder; just different (and probably not better). But post your results. Maybe I'm missing something. Good luck.
    2016 Cayman GTS black/black, PDK, PSE, SC, PTV, X73, PS+, 20" black/polished turbo wheels, full leather, seat ventilation, smoking package, front/back PA w/camera, black brushed AL interior/console, 18-way seats, Bose/Nav PCM, PP+, sport tailpipes, crest on headrests, Alcantara roof lining. MODS: full front+ Suntek clearbra, 35% 3M tint, 7-pc black ZunSport grilles, OEM car cover/rubber mats/rubber trunk & frunk cargo mats/LED markers...

  7. #45
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    Re: Pictures of cut open 981 exhaust?

    Most/all of the aftermarket mufflers for the 981 do separate the left and right side at the tips, so this is nothing "new". So yes, I am trying the same goal with this part of the project: to separate the exhaust pulses. Basically to do something "similar" to this replacement tips you can buy:
    BCVelocityexhaust

    In my current mod I still have the mixing taking place by the center piece that ties left and right side, so even after I do this mod, there will always be mixing taking place - just not at the tips. This mod will definitely change the sound, but I don't know how exactly. Since I have two full/complete 981 exhaust systems, if I don't like these modified tips, I can put the other set I have on the car today.
    2014 Boxster S, DIY Exhaust Mod

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    Re: Pictures of cut open 981 exhaust?

    Quote Originally Posted by wquiles View Post
    OK, I haven't been totally idle, just really busy with family and kid stuff. But time to post on the muffler tip mod .....

    The more I thought about it, cutting and welding was too much work, and would make it harder to do as I would like to. So instead I thought: how about an insert that directs gasses to the two tips instead?
    I removed the pictures for the reply, although I must say, impressive work going on there in Texas!

    Quote Originally Posted by wquiles View Post
    Not "pretty", but it should work really well in separating the muffler gases to each respective tip.

    I finished that piece a couple of weeks ago, so I am now trying to find a quiet morning to do the swap on my '14 Boxster S. I will report back once I do

    Will
    So regarding the bolded statement above... essentially the older style Fabspeedicon style of tip, which by the way sounds great on my car with PSE:

    Pictures of cut open 981 exhaust?-20150612_172202-jpg
    Attached Thumbnails Attached Thumbnails Pictures of cut open 981 exhaust?-20150612_172202-jpg  
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  9. #47
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    Re: Pictures of cut open 981 exhaust?

    Quote Originally Posted by wquiles View Post
    Basically to do something "similar" to this replacement tips you can buy: BCVelocityexhaust
    What you're doing with yours, is what Fabspeedicon offers, as posted below your post, which is completely separate banks... although with the tips that close, it might not sound that different. Who knows. Anyway, your link shows an H-pipe (stock 2), and an X-pipe (dream2). Yours is a 'separate-pipe'. But again, with the tips that close, my guess is any of the 3 systems is going to sound indistinguishable. Let us know, as there's nothing like actual testing.
    2016 Cayman GTS black/black, PDK, PSE, SC, PTV, X73, PS+, 20" black/polished turbo wheels, full leather, seat ventilation, smoking package, front/back PA w/camera, black brushed AL interior/console, 18-way seats, Bose/Nav PCM, PP+, sport tailpipes, crest on headrests, Alcantara roof lining. MODS: full front+ Suntek clearbra, 35% 3M tint, 7-pc black ZunSport grilles, OEM car cover/rubber mats/rubber trunk & frunk cargo mats/LED markers...

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    Re: Pictures of cut open 981 exhaust?

    Yup, pretty much that is the idea. And I also have no idea how it will sound different (if any) from my current mod but I sure look forward to finding out soon

    Now, about the current mod (open muffler, make hole in 90deg tube, and re-weld), I got a co-worker with a 2012 with a Cayman S to take a ride with me, and he's feedback seem to mirror my feedback: nice and louder sound at normal RPMs in town, with good amount of "burbling" when ever gas pedal is released, no droning at all, but under full throttle it sounds about the same as unmodified.
    2014 Boxster S, DIY Exhaust Mod

  11. #49
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    Re: Pictures of cut open 981 exhaust?

    wquiles,

    I had not checked in on you lately, but you're certainly a man with a plan that keeps coming up with innovative solutions.

    I'm still looking forward to meeting up with you sometime soon and checking out your work - thinking of trying to do the same to my Cayman S.

    Thanks,

    StilettoPat
    Frisco, TX

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    Re: Pictures of cut open 981 exhaust?

    It is all my bad for not being able to make any of the PCA events yet. You know, best will probably is meet for lunch. Send me a PM and we can probably meet some point half-way to both of us (I work in Richardson).

    Will
    2014 Boxster S, DIY Exhaust Mod

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    Re: Pictures of cut open 981 exhaust?

    Nice meeting you in person Pat. At least now there is somebody other than my co-workers that have listened to this mod in person. Your Cayman is stunning!


    2014 Boxster S, DIY Exhaust Mod

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    Re: Pictures of cut open 981 exhaust?

    Bumping this thread. Out of curiosity what are those two extra pipes that are attached to the wire on the PSE exhaust? The mufflers themselves look different as well, perhaps that is what is making the difference in the sound. Thanks for posting these BTW

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    Re: Pictures of cut open 981 exhaust?

    Yes, the whole PSE setup is significantly different than the standard mufflers. The extra pipes are connected to the valves. If these valves are closed, the air can't go into these pipes, so it has to go through all of the internal passages (sounds less loud).

    If the valves are open, that allows direct passage of gases from the muffler inlet right into the outlet of the internal tubbing. Since the gases don't go through all of the internal passages (but rather a more direct route), it sounds louder. The button inside the car controls turning that direct passage ON or OFF, thus giving you the two modes of operation.
    2014 Boxster S, DIY Exhaust Mod

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    Re: Pictures of cut open 981 exhaust?

    wquiles, I live in Dallas too (actually Plano) and would love to meet up some time for a starbucks and exhaust show. Been contemplating the Cantrell mod myself, which I believe you pretty much did yourself.

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    Re: Pictures of cut open 981 exhaust?

    Will,

    Thanks again for taking the time out of your day to meet me and letting me hear your handiwork in the form of your modified stock exhaust. It is just a bit louder than stock, but you do hear the burbles on deceleration much more clearly. It might well be a great solution for those that are disillusioned with PSE or aftermarket exhausts that are much louder or produce large amounts of drone. On a separate note, I hope you can find a way to take advantage of some of the drives that the Maverick Chapter puts on around the DFW area - Tom is a great guy that works hard to plan these things - and also of some of the other larger events in the relatively nearby regions of the country - you'll definitely enjoy them.

    Pat Frye
    2014 Cayman S, White

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    Re: Pictures of cut open 981 exhaust?

    Quote Originally Posted by lovetoturn View Post
    wquiles, I live in Dallas too (actually Plano) and would love to meet up some time for a starbucks and exhaust show. Been contemplating the Cantrell mod myself, which I believe you pretty much did yourself.
    Sounds good. Perhaps after the holidays?
    2014 Boxster S, DIY Exhaust Mod

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    Re: Pictures of cut open 981 exhaust?

    You are welcome Pat. Been hard to find time to do the Chapter events, since it seems every weekend I got an activity from my kids. But I will keep trying
    2014 Boxster S, DIY Exhaust Mod

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    Re: Pictures of cut open 981 exhaust?

    Okay, wquiles, you inspired me to experiment with my exhaust. I just acquired a slightly used stock mufflers off ebay. Now the question is - do I cut the whole piece of pipe or just open it up like you did? First might be easier.
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    Re: Pictures of cut open 981 exhaust?

    I agree that cutting it is probably easier than making a hole, but I honestly don't feel it will make any difference in sound. I would go with whatever ends up being easier for you.

    I still "love" the sound of this mod, and everyone who gets in my car agrees that it has a great balance: quiet when you are easy on the gas pedal, and glorious (but not too loud) when you get on it hard

    In fact, I like it so much that even though I did the aluminum insert for the tips, I have not decided to install the new tips as I like it a lot "as is".

    Will
    2014 Boxster S, DIY Exhaust Mod

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    Re: Pictures of cut open 981 exhaust?

    Theoretically - completely removing all visible 90deg pipe - will make it easier for gases to move. So that's what I'm leaning to now
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