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Old 02-04-2002, 01:47 PM   #1
BugBomb
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Default Another Brullen Install

Thanks to Midnx03 (AJ) for letting me and KonKilr participate in his Brullen install. Here are some pics from the install. You may have to save them to your hard drive to view them. Geocities sucks.

Installed Pic#1
Installed Pic#2
View of Primaries
View of Primaries
Full System Pic#1
Full System Pic#2

You can also see the strange obstruction where the driver-side primaries join to the main pipe in the "Primaries" pictures above. This was a concern posted by someone earlier and I thought some people would like a closer look at it.

Also, I got good sound samples from several different exhausts that day, all recorded with the same camera. For example, here is a sound clip of a Brullen-equipped RS revving to around 3-4K, and then a rev from a Borla/Random/Stromung set-up to about the same revs. The sound difference is amazing. Keep in mind it was the same camera, same placement around the car, and same distance from the car.

Brullen - Borla Sound Clip
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Old 02-04-2002, 02:18 PM   #2
AdamSTi
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Dude, check the links.
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Old 02-04-2002, 02:42 PM   #3
Patrick Olsen
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Default

Quote:
Originally posted by ADAMRS
Dude, check the links.
Dude, read what he posted in the first paragraph. I selected "Save Target As" and it worked perfectly fine. Geocities won't let you link to pictures from another site for some reason, but you can save the files just fine.

Quote:
Originally posted by BugBomb
Also, I got good sound samples from several different exhausts that day, all recorded with the same camera. For example, here is a sound clip of a Brullen-equipped RS revving to around 3-4K, and then a rev from a Borla/Random/Stromung set-up to about the same revs.
Wow, that is a really different sound! Of course it's always hard to tell until you hear an exhaust in person, but based on that audio clip I definitely prefer the Brullen sound.

As for the Brullen header, those are the first pictures I've seen of it installed. It may perform great, but I think the design is pretty terrible. It's hard to tell in the pictures, but it appears that the mysterious obstruction is just that they didn't cut a big enough hole in the main pipe before welding on the branch to the driver side primary. Are both primaries obstructed like that, or just one?

Also, is it just my imagination or are the passenger side primaries right beneath the oil filter? Have fun changing the oil! (And yes, I understand you could put something there to keep the oil off the header pipes, but I'd rather stick with my MRT setup, thanks).

Pat Olsen
'97 Legacy 2.5GT sedan
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Old 02-04-2002, 03:00 PM   #4
AJ711
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yes... changing the oil will be "fun" to say the least now, especially since those headers put out A LOT of heat, pretty much right off the bat too... time to invest in some nice long heat resistant gloves...

and the thanks isn't for me, the thanks goes to BugBomb and KONKILR as it only took us 2 hours to take off the old exhaust and install the Brullen setup. Course, the fact that KONKILR is an ASE mechanic for Subaru helped out, oh, a GREAT deal.

120 miles on the car so far and i love the system. it pulls more and in a greater amount of the rev range. the sounds is what i was looking for, and it looks good (course that's not why i bought it in the first place).

now to see how the extended rear O2 sensor holds up. If anyone has any questions about it, feel free to ask me. i'm more than willing to help out at somepoint.

AJ
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Old 02-04-2002, 05:51 PM   #5
BugBomb
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Default

Pat, both tubes had that obstruction. It does look like they just punched two quick holes in the larger pipe before welding the primaries on.

As for the sound, It was hard to pick one when I heard the systems over 5 hours apart. Now that I got them side-by-side, I have to take the Borla sound. I just love the mean sound of that exhaust, like it is ripping the air apart. I liked the Borla's sound more before the high-flow cat from Random tech, but the cat added some power so it is worth it to me. I didn't think the sound would vary so much between exhaust systems.

I am glad you are enjoying it, AJ.
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Old 02-04-2002, 10:46 PM   #6
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I also liked the sound better before the random tech cat. It was a lot lower in pitch but I think I will stick with the current set-up, which works well. Sounds like something was rattling though? Time to crawl under the car this weekend.
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Old 02-05-2002, 08:28 AM   #7
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I didn't hear that rattling noise when I was recording. Maybe I was too distracted by the amazing rumble of that exhaust. I noticed the rattling as soon as I got inside and unloaded the videos. If it is rattling like that, it won't be hard to fix. It's probably touching the same place that my exhaust hits.
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Old 02-05-2002, 08:28 AM   #8
Corey
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That was me that first posted about the horrible juction to the main pipe. I'm glad somebody posted some pics of it. I think mine was a little worse than that. Wish I would have taken some pictures.

Corey
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Old 02-05-2002, 08:33 AM   #9
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I believe AJ is getting a replacement header because of these pictures. More than likely, all the headers were built the same way. It might be worth your time to take the driver side primaries off and get a look down that tube. Of course, you would have to scrape off that silly silicone and re-apply it.

I hate how brullen made everyone apply silicone to that connection. Sheesh, how hard is it to make a gasket for a special flange? Not that difficult.
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Old 02-05-2002, 10:49 AM   #10
MY99 2.5GT
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Did Brullen really make these Headers? I don't see them listed anywhere on there site.

Also why does the Brullen Cat-Back have such a nice black coating on them and the Headers have that ugly pasty looking white stuff?

Brad
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Old 02-05-2002, 11:15 AM   #11
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Quote:
Originally posted by MY99 2.5GT
Did Brullen really make these Headers? I don't see them listed anywhere on there site.

Also why does the Brullen Cat-Back have such a nice black coating on them and the Headers have that ugly pasty looking white stuff?

Brad
The ugly pasty white stuff is the ceramic coating. Apparently it
can be "polished" to a better finish, but I don't know the details
of what you use (0000 steel wool perhaps??)

Stu
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Old 02-05-2002, 01:35 PM   #12
AJ711
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yes i am getting replacements, without any of my say either... it just kinda happened... but i'm not complaining, i'll try to take some similar pics when i get the new ones... and post on their differences...

again... i'm very pleased with this system so far... even with that "obstruction" bugbomb noticed... it's hard to say how exactly that'll affect the flow of exhaust gasses...
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Old 02-05-2002, 05:38 PM   #13
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This being my first real veiwing of the exhaust... what a crappy design. The right bank is set up as a tri-Y design, with a common collector for the 2 primaries. The left bank just dump into the exhaust down the line... no common collector at all. I think any *good* custom header builder would laugh at this. That's just my opinion I suppose... if they perform like they say I guess it dosen't matter what they look like. I liked the Borla/Stromung sound better... much more aggressive and burbely. Just a matter of taste I suppose... I can understand some times when you don't want an aggressive exhaust.
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Old 02-05-2002, 05:59 PM   #14
SubeDonC
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Coreys old system on my car....i just relaced the O2 sensors and the thing works fine, no CE light yet!
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Old 02-05-2002, 06:49 PM   #15
BugBomb
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Default

The CEL is much more common in the 2000+ RSs. In 2000, Subaru changed to a tighter CARB emissions on ALL of their cars. Just about any tinkering with the cats and you will get a CEL. There are ways around it, usually involving wrapping the exhaust. Other fixes are in the works. So you probably won't get a light in a '98.

MrHorspwer,
I couldn't agree with you more. If you followed some of the previous discussions about brullen headers, I was stating very similar objections. I don't see how this sytem can flow very well or even scavenge properly. There is not a single "secondary" diameter pipe in this system. Almost like a 4-1 setup, only not even close.
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Old 02-06-2002, 09:43 AM   #16
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Quote:
Originally posted by BugBomb
The CEL is much more common in the 2000+ RSs. In 2000, Subaru changed to a tighter CARB emissions on ALL of their cars. Just about any tinkering with the cats and you will get a CEL. There are ways around it, usually involving wrapping the exhaust. Other fixes are in the works. So you probably won't get a light in a '98.

MrHorspwer,
I couldn't agree with you more. If you followed some of the previous discussions about brullen headers, I was stating very similar objections. I don't see how this sytem can flow very well or even scavenge properly. There is not a single "secondary" diameter pipe in this system. Almost like a 4-1 setup, only not even close.
Bugbomb is right on the CE thing. It is more prevalent on the
2000+ cars because of tighter ECU monitoring for ULEV
certification. This was unknown to everyone before development
of this header. It is also likely why it wasn't caught on the proto's
as well.

As far as design, we've had this discussion before. No one has
presented any *valid* counter arguement as to why Brullen's
design shouldn't work as intended, other than opinion on how
it looks. What I mean by valid, is real flow analysis. In fact I think
there was a post saying that the optimal length of the "equal
length flow" was less than 36", and what came after was fairly
irrelevant. If it was that important, then why not carry the
exhaust as far back as possible in individual runners? Not even
big-budget race teams do this.

As far as dyno numbers go. Well, given that dynos have such a
huge range from dyno to dyno, and from run to run, I am putting
little faith in the "almighty dyno numbers". They might be alright
for showing relative gains (but then again so does a G-Tech), but
absolute power/torque numbers are always subject to question.


Sigh.....Stu
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Old 04-15-2002, 09:42 PM   #17
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Default sound

Bug,

What flavor of Brullen was that clip of (quiet, med, or loud)?
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Old 04-15-2002, 10:23 PM   #18
AJ711
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medium... their mid grade level. I like the way it sounds on my car.
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