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Old 04-12-2005, 11:07 AM   #1
xcntrk75
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Default Looking for custom exhaust advice…

Hey all, as a few of you have been following I’m in the midst of a WRX swap and now have the need for a custom exhaust setup on my Legacy. In the meantime I’m using the mid-pipe and axle-back from my old MRT setup which was lengthened over 5” to work. Obviously this is a temporary solution as it’s very restrictive (2 Ľ”) pipe and a pretty old muffler setup. But it gets me out of the garage and on the road until I can get a custom system built.

With my new turbo motor I now need a much better flowing exhaust system with as little back-pressure as possible, yet don’t want to be the loudest car on the road sounding like a crap can Honda or something. I’m currently running a catless up-pipe and 3” catless down-pipe, and would prefer to continue with 3” pipe for the rest of the system.

I have a couple shops I’m looking at to perform the work, but think it would probably be best for me to supply the muffler setup, and have the shop just work the 3” tube, hangers, and flanges. So what I’m really looking for are some muffler options. I still need to get back under the car and take some measurements as to what size muffler setup will work between the axle and exhaust tip exit to see how much room I have to work with.

I can do the mechanical and wiring all day long, but when it comes to exhaust and/or fabrication I’m an idiot…

Anybody with helpful advice or words of wisdom, please respond…
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Old 04-12-2005, 11:33 AM   #2
fibuz
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maybe pick up an oem wrx/sti muffler that someone has upgraded is dumping for cheap on the boards and have them make it fit?

The key to keeping it relatively quiet with 3" pipe is going to be the cats really...so you may want to consider welding one into the midpipe as well versus straight piping it...

fibuz
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Old 04-12-2005, 12:10 PM   #3
xcntrk75
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^^^^^
Just to clarify that point, I’m not opposed at all to keeping a CAT as long as it’s a high-flow unit. In fact I was considering either a high-flow cat or resonator in the mid-pipe section anyway, so yes that’s an option.

As for an STI can, that’s a great idea… Cheap and well working (at least good enough for a stock STI) which is good enough for me…
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Old 04-12-2005, 12:14 PM   #4
fibuz
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Quote:
Originally Posted by xcntrk75
^^^^^
Just to clarify that point, I’m not opposed at all to keeping a CAT as long as it’s a high-flow unit. In fact I was considering either a high-flow cat or resonator in the mid-pipe section anyway, so yes that’s an option.

As for an STI can, that’s a great idea… Cheap and well working (at least good enough for a stock STI) which is good enough for me…
I know a guy who one for sale locally with ~7000 miles on it(I believe)...last I heard a deal was pending, but if not I'll forward him this thread so he can get in contact with you...
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Old 04-12-2005, 12:39 PM   #5
iON Performance Inc
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xcntrk75 - If you'd like we can provide you with a BD or BG specific 3" cat-back system
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Old 04-12-2005, 12:42 PM   #6
PHATsuby
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I plan on going with a large resonator for my 3" exhaust, plus a muffler. Hopefully that will keep things fairly quiet, however I am curious too anthony on which muffler to go with, since I have not heard any personally besides stromung and Brullen, so anything you find I would be interested in hearing.

on a side note, what size piping does the Sti come with stock? I know its not ideal but those can flow pretty good i think.

Ben
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Old 04-12-2005, 12:46 PM   #7
iON Performance Inc
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PHATsuby - We're going to be offering 3" cat-backs for the BE/BH on a very limited basis
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Old 04-12-2005, 01:18 PM   #8
omahasubaru
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Quote:
Originally Posted by PHATsuby
.. what size piping does the Sti come with stock?
just under 2.5"

The longer the resonator the better.

I'd go with one of those dynamax bullet race mufflers as your resonator then the muffler of your choice (Brullen or iON).

My experience in making good flowing WRX's with great power/response is that it's tricky, but can be done easily.

A local with full catless exhaust with a Thermal (loud) muffler put in a bullet and it really quieted things down and took the raspy catless edge off as well.

I'm running the TXS stealth back (catted) w/ Prodrive muffler and it is amazingly quiet. Remember that the turbo alone will quiet the car down a lot as it's restrictive... in a way.

I'd see what Jack can do as I'm very pleased with the system we got from them a while back.

Exhaust is something I'm quite found of making flow well and still keeping it quiet. So if you want more input/advice, let me know. I've messed around with lots of set-ups. With my car it's all about the 'Subtle Sleeper' appeal.
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Old 04-12-2005, 01:44 PM   #9
PHATsuby
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thanks for the offer Jack, but im gonna be doing it myself this time I do love my system i got from you before though. Good info, thanks for the tips Omaha.

Ben
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Old 04-12-2005, 01:46 PM   #10
xcntrk75
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^^^^
Yeah like THIS
I was considering something like that as well.

Combined with possibly a muffler like this:


Then just a pain tip like THIS

Although I don't know if I'd have enough depth for that setup...

PS: Forgive my ignorance, but who's Jack?
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Old 04-12-2005, 01:47 PM   #11
omahasubaru
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Jack @ iON Performance
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Old 04-12-2005, 03:23 PM   #12
iON Performance Inc
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PHATsuby - We'll be selling DIY "kits" as well shortly. So if you need a 12 or 18" 3" resonator, 3" SS 90 degree hydroformed mandrels, 3" SS flanges etc we'll be able to provide that to you
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Old 04-12-2005, 04:17 PM   #13
PHATsuby
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well, that is sweet news Jack, I may just be taking you up on that, any idea on pricing? How about bulk discounts, im also gonna need probably 4 STi header flanges and some various smaller diameter 304 bends to do the headers with.

good finds on those anthony, they look nice. Are you doing SS or mild?

thanks

Ben
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Old 04-12-2005, 04:25 PM   #14
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PHATsuby - Here's the info for you -> http://www.ionperformance.com/uni.html

List isn't totally complete yet. Your best bet is to use our tight radius hydroformed mandrels for the area underneath the rear suspension. It'll allow you tuck things better. You'll need ~3 bends to do this. (Cat-back)

As for the header, are you swapping the EZ30 on there? If so we can get the flanges made for that, though it'd be one-off custom work. We have various diameter and various radius tight mandrels available as well. All in 16 gauge T304SS.
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Old 04-12-2005, 04:26 PM   #15
xcntrk75
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Prolly stainless, whichever holds up longer…

Jack, I too need some 3” 2-bolt flanges for my DP as they’re incredibly hard to find…
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Old 04-12-2005, 04:42 PM   #16
iON Performance Inc
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xcntrk75 - No problem, we've got everything listed on our DIY page basically available. The 3" flanges are something we use lots for our other components. We also have our own stainless mufflers & resonators as well if you're looking to go "custom".

Last edited by iON Performance Inc; 04-12-2005 at 04:55 PM.
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Old 04-12-2005, 05:34 PM   #17
PHATsuby
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are there bulk discounts for X amount of piping or dollars? those are higher than i have seen elsewhere. Also are the resonators perforated or louvered cores?

How about this, you guys can make me a couple header flanges, then use it for future headers, and then i give props to Ion for the setup

thanks for the info Jack

Ben
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Old 04-12-2005, 05:47 PM   #18
GTBGUY
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Cool stuff H6 and turbo in a BE. Definately cool
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Old 04-12-2005, 05:51 PM   #19
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PHATsuby - There's a "bulk" discount available however it depends on how much you get. All of our tubing comes in 20ft lengths, the price includes the S/C for deburring and cutting to the length you want. (We can only ship up to 60" in length). That's why the price seems higher, but if you were to compare how much other places charge on their S/C then you'll see we're considerably cheaper. Our stainless is welded seamless piping and mill finish. (Our stainless is mainly from Japan, Germany or Italy. Some is Canadian )

The resonators are perforated cores. Our mufflers are also perforated & packed w/ SS & ceramic packing.

As for the header flanges, we won't be making anything for the H6. We do offer stainless header flanges for the dual ports

Drop us a line with your "list" and we'll see what we can do for you
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Old 04-12-2005, 06:01 PM   #20
PHATsuby
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cool thanks will do, sorry it was a semi hijack Anthony, hopefully some of this info helped you out too.

Ben
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