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Old 10-24-2004, 05:04 PM   #1
ilmaestro
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Default Brullen equal length header/cat for NA impreza - first impression

So I recently picked up a used brullen equal length header that was in very good condition, along with a new brullen high flow cat to match (Both designed for a dual port NA an impreza). The cat has a 2.5" opening where it meets the midpipe, but my Stromung muffler piping is only 2.25", so I had a 2.25" midpipe made with an inline 2.25" magnaflow circular shaped resonator. Also just to mention, my car has the stock intake right now.

First, the sound up around the front and middle of the car has increased. My car has the stock intake, so the noise up around the front of the car was quiet previously, but now has a nice medium throaty growl, which is louder when I'm hard on the gas and mostly quiet when I'm light on the gas. The headers make a very mean sound, not at all ricey, but rather very throaty and agressive. The rear section of the car near the Stromung muffler sounds about the same as it did before with the muffler and the stock exhaust. It's very low and grumbly, and didn't seem to increase in volume probably due to the magnaflow resonator in the midpipe.

Besides the added sound up front from the headers when I'm on the gas, I've noticed another sound which seems to be coming from the high flow cat when I let off the gas. It's a very raspy metallic-like sound that comes only when I let off the gas when the RPMs drop during a shift, or when I rev the motor. It's not noticeable inside the cabin, but it almost sounds like the flutter of a blow off valve in its raspiness. I can't tell if it goes away when I'm driving or if it only occurs when I'm parked and rev the engine, but I'm pretty sure the sound is coming directly from the cat area. I'm also not sure if this is normal.. but I'll maybe look into it more later.

Now for the performance. I've only driven the car a bit with the new setup since it's new, but the performance increases are instantly noticed. Previously, my car would tend to bog occasionally or hesitate on fast launches, and now seems to be a bit smoother in the lower RPMs in the first few gears. When I step on it and rev to redline working through the gears, the car pulls hard all the way to the redline, and has a very smooth hard pull all the way, with no real weak points anywhere in the RPM band. It's not a complete head jerking addition of power, but the car feels siginificantly stronger and pulls noticeable harder and smoother all the way through. My friend who sits in my passenger seat regularly when I drive the car also noticed the significant increase in power.

This is the first power-adding mod I've ever done to a car, so I'm not an expert at gauging these things using the 'butt-dyno', but overall I'm pretty happy with the results. It's nothing head jerkingly spectactular like turboing the car, but it definately makes the car feel much smoother and much stronger. I get the feeling it should have been like this stock.

Hope this was helpful. I might followup with more impression later after I drive the thing some more.

jonathan
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Old 10-24-2004, 05:13 PM   #2
96Imprezadent
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i hear the raspiness is normal. My fix would be to eliminate all cats involved!
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Old 10-24-2004, 10:25 PM   #3
ilmaestro
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Quote:
Originally Posted by 96Imprezadent
i hear the raspiness is normal. My fix would be to eliminate all cats involved!
Hah. Yeah. The raspiness might be normal, but it sure sounds wierd to me. Like two pieces of thin sheet metal rattling together whenever I let off the gas!
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Old 10-24-2004, 10:26 PM   #4
96Imprezadent
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i have that noise with the stock cat, not to loud tho. It gets louder with a high flow, thats what im told
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Old 10-24-2004, 11:42 PM   #5
ilmaestro
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Quote:
Originally Posted by 96Imprezadent
i have that noise with the stock cat, not to loud tho. It gets louder with a high flow, thats what im told
When does it occur for you? For me it is whenever I let off the gas.
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Old 10-25-2004, 12:04 AM   #6
96Imprezadent
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yeah its usually then. I can only hear it when i have the door open and i lean outa the car. The engine vibrates the most when its decelerating.
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Old 10-25-2004, 12:40 AM   #7
ilmaestro
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Quote:
Originally Posted by 96Imprezadent
yeah its usually then. I can only hear it when i have the door open and i lean outa the car. The engine vibrates the most when its decelerating.
Any idea what causes it? I wouldn't think it's engine vibrations, because it happens when upshifting, which isn't necessarily decelerating... the RPMs drop though, and the noice occurs. When I'm crusing with the doors closed I can't hear it, but when I roll down the window I can barely hear it and when I drive next to a curb or a wall or something I can hear it LOUD whenever I let off the gas.
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Old 10-30-2004, 09:42 PM   #8
ilmaestro
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Thought it was worth posting an update.. I just saw that one of the freaking bolts that connect the cat and header flanges is missing!!!! So.. I'm thinking there might be a leak, thus the loud noises I'm experiencing. More to follow.

j
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Old 10-31-2004, 02:42 AM   #9
soulcrusher500
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If you have not found a solution yet, I have an idea. I used to have the same header with the Brullen exhaust on my OBS. After installing it, my car made a similar sound under decelaration. Almost like a loud grinding of metal. Come to find out it was a bolt holding the heat shield in place. When I would slow down the exhaust would shift forward just enough to let the cat hit that bolt and vibrate. One of the worst sounds I have ever heard from my car.

I just took the bolt out and removed the heat shield.

Hope that helps.
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