Pictures of cut open 981 exhaust?
Page 1 of 3 123 LastLast
Results 1 to 20 of 60

Thread: Pictures of cut open 981 exhaust?

  1. #1
    Join Date
    Mar 2016
    Location
    TX
    Posts
    88
    Likes (Given)
    3
    Likes (Received)
    23
    Downloads
    3
    Uploads
    0

    Pictures of cut open 981 exhaust?

    I am planing an exhaust mod, and although I have looked, I have not yet found a picture of the innards of the non-PSE 981 muffler/exhaust. Any leads/links, please?
    2014 Boxster S, DIY Exhaust Mod

  2. Remove Advertisements
     

  3. #2
    Join Date
    Mar 2016
    Location
    TX
    Posts
    88
    Likes (Given)
    3
    Likes (Received)
    23
    Downloads
    3
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    For those curious, here is the OEM 981 exhaust, next to the PSE:







    And here is the cutout of the extra set of OEM 981 mufflers, which I intend to modify for a PSE-like, always-on sound:
    2014 Boxster S, DIY Exhaust Mod

  4. #3
    Join Date
    Nov 2015
    Location
    Burnaby, BC
    Posts
    305
    Likes (Given)
    80
    Likes (Received)
    56
    Images
    1
    Downloads
    1
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    this is interesting, pls keep going and taking photo of your project progress.

  5. Remove Advertisements
    Planet-9.com
    Advertisements
     

  6. #4
    Join Date
    Mar 2016
    Location
    TX
    Posts
    88
    Likes (Given)
    3
    Likes (Received)
    23
    Downloads
    3
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    Will do. Here are a couple more pics:






    2014 Boxster S, DIY Exhaust Mod

  7. #5
    Join Date
    Mar 2016
    Location
    TX
    Posts
    88
    Likes (Given)
    3
    Likes (Received)
    23
    Downloads
    3
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    OK, so I ordered the .023" mig welding wire yesterday. That will allow me to weld the cover back up.

    Now, as to the "mod". My current plan is to make several small holes on that pipe in the first chamber, so that exhaust gases can flow into the flared pipe, which goes out to the muffler tips. With this mod, some of the gases still are going to flow into the main muffler chamber (and the cross/connected piece that ties both left and right), but the majority of gases will head towards the main exit.

    This "mod" is similar to mods I have seen done on 911 mufflers where they weld a new piece tying the main input tube to the output tube, creating a "Y" so that many of the gases are diverted to the exhaust tips while some goes into the muffler chamber(s):
    Yet another PSE style exhaust mod - Rennlist Discussion Forums

    and here, post #4:
    PSE sound with minor mod to stock exhaust


    I have a couple of days while the welding wire gets here, so I can consider other ideas. Thoughts?


    Will
    2014 Boxster S, DIY Exhaust Mod

  8. #6
    Join Date
    Jan 2016
    Location
    Houston, TX
    Posts
    93
    Likes (Given)
    22
    Likes (Received)
    15
    Downloads
    1
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    Will,

    I'm very interested in your progress and results. I'd love a little more bark but have a hard time justifying $3k for the PSE, although the on-off feature would be nice.

    Where in the great state of TX are you? I'd like to hear your car when the mod is complete.

    Tom
    2013 Boxster S

    2010 G37, 2010 XC70, 2001 Wrangler
    2014 Moto Guzzi Stelvio

  9. #7
    Join Date
    Mar 2016
    Location
    TX
    Posts
    88
    Likes (Given)
    3
    Likes (Received)
    23
    Downloads
    3
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    I am in the Dallas area, just joined the Maverick region PCA.

    Quote Originally Posted by toma nova View Post
    I'd love a little more bark but have a hard time justifying $3k for the PSE, although the on-off feature would be nice.
    That is "exactly" why I am doing this mod. I can't afford the $3K for the PSE+install. So these OEM mufflers (with 5K miles) I got used on ebay for $289 is a viable project since I can do welding myself.

    I have posted this thread on two Porche 981 forums, and I am surprised there is so little interest. Similar threads on 991 cars are epic-long, but not on our cars. Maybe just fewer Boxster/Cayman owners wanting this mod?
    2014 Boxster S, DIY Exhaust Mod

  10. #8
    Join Date
    Mar 2016
    Location
    GA
    Posts
    339
    Likes (Given)
    81
    Likes (Received)
    39
    Downloads
    2
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    Quote Originally Posted by wquiles View Post
    Maybe just fewer Boxster/Cayman owners wanting this mod?
    I would say more along the lines of many people either already have PSE or just went straight to aftermarket. Although it is just speculation I feel like there are likely way more base 911 with few options selected since they were probably squeezing their wallets just to get the 911.
    2016 Cayman GTS
    Mahogany | Manual | PASM | Espresso Natural Leather | PTV | PCCB | MF Wheel | Heated/Ventilated | 18-Way | Folding Mirrors | 20" Turbo | CDR Plus | Entry & Drive | Dimming Mirrors | 2-Zone Climate | Light Design | Seat Belts Beige
    Ordered 02.20.16 | V250 03.01.16 | V300 04.04.16 | PEC Atlanta Delivery 05.24.16

  11. #9
    Join Date
    Mar 2016
    Location
    TX
    Posts
    88
    Likes (Given)
    3
    Likes (Received)
    23
    Downloads
    3
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    Quote Originally Posted by squeaks5635 View Post
    I would say more along the lines of many people either already have PSE or just went straight to aftermarket. Although it is just speculation I feel like there are likely way more base 911 with few options selected since they were probably squeezing their wallets just to get the 911.
    That makes sense - thanks
    2014 Boxster S, DIY Exhaust Mod

  12. #10
    Join Date
    Jun 2015
    Posts
    14
    Likes (Given)
    19
    Likes (Received)
    1
    Downloads
    1
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    I am very interested in your progress on this also. I always wondered about the Cantrell exhaust mod. Because what I read there is no sign of any exterior modification when the exhaust is returned after the mod. Could they be just running a long drill bit down the pipe and poking a hole in the elbow that is in the chamber?

  13. #11
    Join Date
    Mar 2016
    Location
    TX
    Posts
    88
    Likes (Given)
    3
    Likes (Received)
    23
    Downloads
    3
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    Quote Originally Posted by Jessesre View Post
    I am very interested in your progress on this also. I always wondered about the Cantrell exhaust mod. Because what I read there is no sign of any exterior modification when the exhaust is returned after the mod. Could they be just running a long drill bit down the pipe and poking a hole in the elbow that is in the chamber?
    They can cut a piece of that incoming pipe, or make some hole/holes on that incoming pipe, or weld a new tube between that one and the one that feeds directly to the tips, etc. If you google "Porsche Modified Muffler" you will see there are lots of ways to do these mods. Of course, they most likely tried several mods until they found one that works well with no drone. We can't know unless somebody cuts open a modified one

    I of course plan to record audio before and after. Lets see how it turns out. I got the confirmation note from the shipment of the 0.023" mig wire, so maybe by this weekend I can get to "work" on this again.
    2014 Boxster S, DIY Exhaust Mod

  14. #12
    Join Date
    Oct 2008
    Location
    IN
    Posts
    532
    Likes (Given)
    197
    Likes (Received)
    85
    Downloads
    11
    Uploads
    0
    My Classifieds

    Re: Pictures of cut open 981 exhaust?

    I'm subscribed...I'd like to see how this comes out.


    '14 White/Black 2.7 6spd 19" Boxster S wheels Premium pkg w/14way Bi-Xenon Sport Design steering wheel Infotainment pkg PCM

    The "car thing" isn't about how much a car might be worth, or how much you're sure to make on it. It's about how it makes you feel when you're behind the wheel. It's about how it makes you feel when you walk up to it, or walk away from it. Or even when you wash it by hand. ~Dr. Bud E. Bryan

  15. #13
    Join Date
    Mar 2016
    Location
    TX
    Posts
    88
    Likes (Given)
    3
    Likes (Received)
    23
    Downloads
    3
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    Alright, the welding wire arrived early!
    (.023" for the exhaust and other thin metal; the .030" (and .035") wire are my go-to-wire for most projects with thicker steel):
    2014 Boxster S, DIY Exhaust Mod

  16. #14
    Join Date
    Aug 2012
    Location
    PA
    Posts
    318
    Likes (Given)
    85
    Likes (Received)
    152
    Images
    44
    Downloads
    4
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    Thanks for the pictures. This is all I could think about after seeing that - https://www.youtube.com/watch?v=Mj73yYe3AY8
    You blow through here, the music goes round and round, woah-o-o-o-o-oah and it comes out here.
    William
    Owner: 2014 981 CS | Rhodium Silver | Sport Seats Plus - Black Lthr | 6MT | PASM | SC | PSE | Info Pkg Bose | Conv Pkg | ParkAssist F&R | Seat Vent | SportDesign Wheel | White Dials | Ext Paint Pkg | Model Delete | Bi-Xenon PDLS | Voice Control | 19in BS Wheels : 9/14 - Delivered : Mods - SSK, RoofCam, FVD Brombacher headers, Cobb Stg 2.

  17. #15
    Join Date
    Nov 2015
    Location
    Burnaby, BC
    Posts
    305
    Likes (Given)
    80
    Likes (Received)
    56
    Images
    1
    Downloads
    1
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    To OP:
    1. Why mild steel for the weld wire? won't they eventually rust vs more durable SS?
    2. Did you see any glass pack wool inside the mufflers?
    Tks.

  18. #16
    Join Date
    Mar 2016
    Location
    TX
    Posts
    88
    Likes (Given)
    3
    Likes (Received)
    23
    Downloads
    3
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    Quote Originally Posted by Cayman Ed View Post
    To OP:
    1. Why mild steel for the weld wire? won't they eventually rust vs more durable SS?
    2. Did you see any glass pack wool inside the mufflers?
    Tks.
    1. Since I am keeping my stock/OEM "as is" and I am modifying/experimenting with this extra set, I am not worried about long term rust. That, and I don't want to get another gas bottle just to MIG SS. This is meant to be a fun, simple project with as low cost as possible :-)

    2. None whatsoever. Just like they look in the pictures above.
    2014 Boxster S, DIY Exhaust Mod

  19. #17
    Join Date
    Mar 2016
    Location
    TX
    Posts
    88
    Likes (Given)
    3
    Likes (Received)
    23
    Downloads
    3
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    Horrible job in the welding, but it is sealed. On with the pictures ...

    Started with these 1/2" holes:



    Then cut the "triangle" part completely off:



    Several years welding, but first time welding thin wall (need more practice!). Needed to buy correct tip for the thin wire:



    Spot welded, then welded pieces. Had to run over some sections again to close the small leaks I found with the water:





    Here is my water testing setup. Keep touching up, fixing small/tiny leaks until there were none:



    How does it sound? Have no idea. Run out of time to install today. Will do tomorrow morning (Sunday). Fingers crossed!

    Will
    Last edited by wquiles; 09-04-2016 at 12:15 PM.
    2014 Boxster S, DIY Exhaust Mod

  20. #18
    Join Date
    Feb 2014
    Location
    OH
    Posts
    1,257
    Likes (Given)
    54
    Likes (Received)
    340
    Images
    50
    Downloads
    28
    Uploads
    4

    Re: Pictures of cut open 981 exhaust?

    Great work!

    I am going to open up my Cargraphics muffler today, just to see what caused it to develop severe backpressure. I plan to repair it and weld it back up.

    V6

  21. #19
    Join Date
    Mar 2016
    Location
    TX
    Posts
    88
    Likes (Given)
    3
    Likes (Received)
    23
    Downloads
    3
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    OK, all done. Swapping the exhaust doable by one person, but would have been easier with two!:


    Even though I only have 8K miles, I still used my favorite fluid for frozen nuts:




    The factory unit comes out as a single unit:



    The sound? It got a "little" louder from inside the cabin - not yet quite as loud as I was hoping. Looks like I would need to try something more drastic between the input and output pipes (like the factory PSE system).

    No drone to report so far (tried city and highway - my car is manual, I always drive in Sport + mode). I can hear a little bit more of the "burble" sounds on downshifts, but not nearly as much as the video clips from the PSE.


    Here are two clips, before and after, in both the engine was already warm. You can hear a slightly deeper tone at idle on the modified mufflers. On this short test, at the higher RPMs the modified sounds to me even a little bit quieter, but I will report more as I drive it over the next week on my normal routine/commute.

    Original:


    Modified:
    Last edited by wquiles; 09-04-2016 at 12:21 PM.
    2014 Boxster S, DIY Exhaust Mod

  22. #20
    Join Date
    Mar 2016
    Location
    TX
    Posts
    88
    Likes (Given)
    3
    Likes (Received)
    23
    Downloads
    3
    Uploads
    0

    Re: Pictures of cut open 981 exhaust?

    Drove it again this afternoon, but with my daughter, and we both felt the exhaust was definitely louder than before, but she felt it was not obnoxious, nor too loud. Heard more burbles on the downshifts this time.
    2014 Boxster S, DIY Exhaust Mod

  23. Remove Advertisements
     

Page 1 of 3 123 LastLast

Similar Threads

  1. Where are all of the 981 pictures? Post pictures of your 981 here!
    By BoxsterHopeful in forum 981 Cayman and Boxster Pictures and Video
    Replies: 856
    Last Post: Yesterday, 02:48 AM
  2. Pictures of 981's with varying suspension setups!
    By Rac10000 in forum 981 Cayman and Boxster Pictures and Video
    Replies: 43
    Last Post: 06-08-2014, 11:42 AM
  3. Any Pictures of Escort 9500ci installed in 981s
    By Keadog in forum 981 Cayman and Boxster Electronics
    Replies: 31
    Last Post: 11-06-2013, 05:19 PM
  4. Pictures of the 981... in Yellow!
    By Westcoaster in forum 981 Cayman and Boxster Pictures and Video
    Replies: 0
    Last Post: 03-05-2013, 07:38 AM
  5. Post a Picture of your Cayman Spec Here
    By K-Man S in forum 987 Cayman and Boxster Chat
    Replies: 22
    Last Post: 09-17-2005, 07:14 PM

Tags for this Thread

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  
Back