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3 inch Turbo back with Resonator and Twin Tip Muffler?

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fergulus

15+ Year Contributor
205
1
Dec 18, 2007
Portsmouth, UK, Europe
I currently have a cheaply made 3" downpipe, with a resonator and Borla twin tip muffler on the last section. The pipe was not mandrel bent, so it gets smaller on turns. The resonator was badly welded in, and the flanges are all 2.25" or 2.5", which defeats the purpose of a 3" exhaust. Also, there are random 3" sections welded in to attach the muffler and resonator.

My problem is thus... I love the sound that my exhaust makes, and it looks ALMOST stock. I absolutely do not want a coffee can exhaust, yet that is all that I seem to find for sale for the DSM. They do not have the low and purring sound that my current setup is, but after a detailed inspection of my setup (from the previous owner, the cheap bastard) I just can't keep it!

Does anyone know of a twin tip muffler that is not gawdy and sounds good? I want the low throaty rumble that I have now, and I do not want it to look like my car has been moderately modified. I have looked at the big companies, and all they seem to sell are the coffee can style mufflers, which I think sound terrible on a 4 banger!

Would I have to just buy a resonator and muffler, and have someone custom fab my piping? I am not looking for the cheapest route here, I want a full 3" o2 back exhaust system with no catalytic converter and the above mentioned parts.
 
I'm currently going through the exhaust build process also, and doing a stainless catback from scratch, but there are many more options for the 2g. I'd say take a look around on the vendor's sites, find something you like, then call them and ask them if they have any that 'aren't quite right.' If you're lucky, you'll be able to find a nice system that got the round style muffler scratched up/dented up at some point, but everything else is ok and you could get them to cut you a deal on it. I would also think that some sites would sell you the piping all bent and welded without a muffler attached, or maybe a different one if you can find it on their site. Are your existing resonator and muffler both 3" units? If they're in good shape, with some pipe on the ends of them left, you could cut them off the old system and get them welded into the new system. I'd also say to look at a metal core cat, maybe something like this. Punishment also sells a nice 3" downpipe. I have the 1g version laying here waiting to go on the car, welds are really nice, looks like good quality work.
 
The biggest problem you'll have is that you won't know what it'll sound like until you build it or have it built. And if it's not what you wanted, then what? Try again? I'd guess that your best hope of having a nicely constructed exhaust that sounds the same as your current exhaust would be to reuse the muffler and resonators (or buy new ones of the same model) and then have full 3" mandrel-bent SS pipe, flanges, and flex section welded by someone that knows how to TIG weld and takes pride in their work.

But at the same time, you shouldn't forget the saying, "if it ain't broke, don't fix it".
 
I had just checked out that vibrant muffler you are talking about, and I'm still up in the air as to whether a black muffler would attract more or less attention than a satin muffler. Does anyone have pictures of a black muffler on their 2g?

As to reusing my resonator and muffler.... there is not enough extra piping to reuse them, and the welds are rusting heavily. I do understand the old adage "if its not broke, don't fix it" but every time I put my car on a lift my exhaust makes me cringe :banghead:

As far as resonators go, does anyone have any experience with different brands? There is no way for me to know what brand the current setup is.
 
The last setup on my 1g was a custom made 3" exhaust from a local exhaust shop. 3" back to a resonator where the cat was back to a 3" in magnaflow with 2 2.5" outlets. He then welded on two chrome tips at an angle (optional) out the back. Sounded real mean and throaty. I was going to go back with the same setup on this one since I liked it so much. But, he raised his rates and I got a hell of a deal on the full SS megan exhaust.

Here's the muffler

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Two of these tips:

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I can get you some pics of my setup once I get home from work.
 
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i just got back from my local muffler shop, they bent up a 3" o2 back exhaust on my 1g and it came out bitchen!, they use 3" flanges and have awsome welding skills, i'm running a 3" dual chamber but its a single out, it sounds awsome and you can still hear the turbo whistle while it idles, plus its still quiet in the low rpms as to avoid tickets. i've noticed a BIG difference in spool time with it, check out "Ojai valley Muffler" man they did a completely fantastic job! Picks on my myspace "live life to the fullest" ojai, CA check it out man!:thumb:
 
Here you go, this is what I had when it was all said and done. I was going for more of a staggered tip look but the exhaust guy didn't understand. Looked good anyway.

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That looks pretty decent. Im still a go for the single exit fart can as long as it sounds mean... My buddy had a dual exit series 40 flowmaster and it was routed back into one before the end and it was mean as .....
 
Here's what I did. Muffler was scuffed up with 200grit and painted with flat black BBQ paint.

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Having a short section of 2.5" exhaust does NOT mean the rest of that otherwise 3" exhaust is now relegated to flowing like a 2.5" exhaust. It means you have whatever additional flow loss associated with that neck down or section. You could have a properly designed neckdown to say 2.5" and if it was designed correctly with an ideal nozzle shape and the ideal diffuser shape, would flow nearly equal to a full 3" exhaust. The total flow loss is the summation of the individual flow losses throughout the entire system. Every system flows different because of this.
 
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