Well, it's taken forever, but I've finally done it.
After much research and experimentation, I think I've found what I think is a perfect custom exhaust system for my lude. My goal: build as economically as possible the most quiet 2.5" dia straight-through system for the lude possible. The current setup I've stumbled upon has far exceeded my expectations!
I'm just thrilled right now to know that it is even possible to do this with the lude! In three words, this system is amazingly DEEP, SMOOTH, and QUIET.
As obnoxious as straight-through 2.5"systems can sound, my ideal was to get something that sounds like my former Apex'i WS; as hard as it is to believe, what I ended up with sounds like a V6--even better than a WS. I am extraordinarily picky, and don't think I say this inaccurately.
The review: On idle it is practically silent, with an almost subsonic bass hum. On acceleration, it emits a deep quality tone, not loud, not anywhere close to a rasp. Slightly louder than a WS, but exactly the pleasing throaty bass you want to hear. And the more you press down on the accelerator, the deeper and deeper this baby gets, just like a V6. It never gets that cheap boomy/struggling quality; instead it sounds robust. When you let off the accelator there's just a hint of more throaty bass. On WOT, all you hear is engine, and just a slight bassy growling from the back. On cruising no matter what speed it is nearly silent, no drone. Perfect. For an idea of the sound, it's very similar to (but quieter than) the clip that plays when you go to magnaflow.com.
The difference between a free-flowing straight-through system and a baffled/more restrictive one is remarkable. The whole RPM range is totally smoothed out, so smooth that sometimes you can't even tell when you've crossed over to VTEC. I still have to wire my VAFC and get a dyno, so these comments are subjective right now.
In brief, I went through 3 mufflers and tips to get here. First, I had a Magnaflow 5" x 8" x 18" muffler. Nice, that same magnaflow smoothness, but was too boomy/loud on acceleration during street driving for my taste. Drew attention. I noticed that it strikingly quiets down after about 1-2 months of break in, but still too loud for me even after this. As I've said, I think that many people would actually like this and be perfectly satisfied. Probably very close to a Thermal. But I decided to try the Hytech Twin Loop 2.5" muffler which had gotten rave reviews by Artifex, I think based on a 2.25" system pre-muffler. I think having 2.5" pre-muffler makes a difference, since I found the Hytech to be in fact surprisingly louder than the Magnaflow, more prone to vibration/not as smooth, and much more noticeably restrictive. I don't want knock this muffler, since it is a beautiful piece and worked amazingly for Artifex; but for my particular setup it was as described.
I decided to go back to Magnaflow but with a bigger can this time, from 5"x 8" x 18" to a giant 5" x 11" x 22". It's a behemoth for trucks. But believe it or not, it just fits in there! It can be slightly embarrassing, but paint that baby flat black and no one will ever know. Oriented correctly there is enough clearance for no rattles and adequate play. I also added a Magnaflow resonated tip. Not sure how much its contribution is, but it looks great. It is the results with this can and tip that I'm so clearly blown away by.
So......
If you'd like to take the time build this same system, here is a full parts list and the cheapest prices I found. Keep in mind that some may consider that I've made significant performance compromises in this system as I've placed a resonator in every component possible: the cat itself, 2 actual resonators, a giant muffler, and a resonated tip. Theoretically, yes, flow will be somewhat worse with all this perforated pipe. But again, it obviously provided me with the sound I want, it feels plenty unrestricted, paired with my header I feel large gains, and--for what it's worth--Magnaflow has numbers showing flow differences between their resonators and straight pipe are insignificant.
1. High-Flow Cat
Magnaflow/Carsound 94406 with built-in Resonated Core, 2.5" ID, 4" x 7" x 15.5"
$68.47 from
www.fulllineexhaust.com
2. Resonators
2 Magnaflow 14416 Stainless Steel Resonators, 2.5" ID, 4" round, 14" long
$58.35 each from
www.fulllineexhaust.com
3. Muffler
Magnaflow 14576 Stainless Steel, 2.5" ID, 5" x 11" x 22"
$108.12 from
www.fulllineexhaust.com
4. Exhaust Tip
Magnaflow 35175 Stainless Steel Resonated Oblong Rolled Edge, Angle Cut Tip, 2.75" x 5.25" x 9.75"
$52.26 from
www.fulllineexhaust.com
5. Tubing
2 T304 Stainless Steel 2.5� OD, 16GA, 90 degree long bends, 5.187 CLR
$19.08 each from Vertex Industries on Ebay, these are for the S bend
2 T304 Stainless Steel 2.5� OD, 16GA, 45 degree short bends, 3.75 CLR
$11.24 each from Vertex Industries on Ebay, these are for the axle-back section
4 ft T304 Stainless Steel 2.5" OD straight pipe
$7.18/ft from Vertex Industries on Ebay, some extra in case there's a goof
6. Hardware/Misc
02 Bung for after-cat position
$5 at local muffler store, needs to be welded onto cat
4 3-bolt flanges and nuts/bolts, cold rolled steel, for a total of 2 joints
$20 at local muffler store, stainless steel flanges are too expensive, at $35 each piece!
2 3-bolt flange gaskets
$2 each at Murray's
Stainless Steel Hangers
Do not buy these (ridiculously expensive)! Just have whoever is welding your system bend some out of stainless steel 3/8" wire, willl need 5 total
Rustoleum High Heat Flat Black Enamel
$4 from Home Depot
7. Labor to Weld Components
~$200 at local muffler shop, or whatever you can get; I'd recommend slip joints (welded) rather than butt welds
Total Cost
$345.55 from
www.fulllineexhaust.com (cheapest prices by far, free shipping over $50!)
$82.18 + S/H (say $92.18) from Vertex Industries
$34 for hardware from local stores
$200 welding cost
_________________
$671.73
The system can be had for significantly cheaper by choosing aluminized steel instead of stainless.
I will post pics as soon as some finishing touches are made. But you can get an idea from my previous threads on this topic. Can also try to make an audio recording.
Comments are welcome, and I'd be glad to answer any questions. Hopefully you guys can benefit from all the money, time, and patience I've had to put into this!!!
But now our community knows a quiet 2.5" can be done!
Happy luding!
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