Welditup Posted August 18, 2015 Report Share Posted August 18, 2015 A couple videos taken on a closed coarse, haha.25-80mph 50-100mph Link to comment Share on other sites More sharing options...
Welditup Posted August 26, 2015 Author Report Share Posted August 26, 2015 Here's a video of the exhaust sound after the exhaust mods. Link to comment Share on other sites More sharing options...
Exekiel Posted August 26, 2015 Report Share Posted August 26, 2015 That's got a great throaty sound. What were the exhaust mods? Link to comment Share on other sites More sharing options...
Welditup Posted August 26, 2015 Author Report Share Posted August 26, 2015 I made my own exhaust outta sections I bought from an autoparts store. I bought one 3" bend for the downpipe $38, 3" flepipe $30, 3" pipe (32inches long)$42, and junkyard 2.5" to the stock muffler(free). I used a cut-off wheel and cut open the stock muffler to remove 75% of the exhuast insulator and removed all the guts inside. I was just guessing on the muffler part and I think I hit it spot on, sounds great. There's zero exhaust drone in the upper rpms. The only drone I have is below 2,000 rpm Link to comment Share on other sites More sharing options...
Exekiel Posted August 26, 2015 Report Share Posted August 26, 2015 Wow! This kind of thing is super exciting and motivating for me to hear. Those mods sound like they not only improved sound but probably noticeable increase in hp and mpg. All for really cheap! We're the hp gains pretty significant like I'm thinking they would be? Was the down pipe already bent correctly when you bought it? Link to comment Share on other sites More sharing options...
Exekiel Posted August 26, 2015 Report Share Posted August 26, 2015 So a pretty visual guy and was trying to find diagram of the exhaust system and found this http://www.swedishautoparts.com/S40/Volvo-S40-exhaust-parts-turbo.htmlto be pretty good. Now the downpipe is the piece that connects to the first cat right? This might be really noob but what does it connect to on the other side? Did you keep the stock cats too? Link to comment Share on other sites More sharing options...
1clean00 Posted August 26, 2015 Report Share Posted August 26, 2015 The stock setup has the primary cat as part of the turn coming off the turbo, then to a tiny flex section, then through the 2nd cat, then through a pair of resonators/silencers, then through a large muffler. A few guys have seen big gains just by changing the flex section to the back muffler with 2.5" pipe. This would eliminate the stock flex pipe, 2nd cat, and resonators. I think the gain though was something like 10hp and 18ftlbs? A true performance downpipe will have a nice bend off the turbo that maintains its radius (mandrel vs. crush bent) into an oversized flex piece and hi-flow cat. Then from the hi-flow cat to a nice sports muffler in the back. 3" from the turbo back would give the most sound, but most setups are fine going to 2.5" after the cat and through the back muffler. Link to comment Share on other sites More sharing options...
Welditup Posted August 26, 2015 Author Report Share Posted August 26, 2015 Downpipe is mandrel bent and made from scratch. There was a noticeable difference after I did the exhaust. Mostly noticed it at midrange rpms into upper rpms. Next day I have off I'm tackling the cat-delete and a manual exhaust cut-out. Eventually I would like to get a boost activated cut-out. If any of you guys live around new Hampshire I can build the exhaust for you. Link to comment Share on other sites More sharing options...
Welditup Posted August 27, 2015 Author Report Share Posted August 27, 2015 You can get by with a portable welder but make sure your metal is sanded down very clean to allow for better penetration. The hard part is making your angle cuts right. Go slow and take your time because you don't want more than an 1/8" gap on your seams. took me 5 hours to make mine,ugh. Also, just tack weld your sections together as you go, do not try to weld your exhaust as much as you can with it still hanging there on the car....you could start a fire from the heat from the welds. Typically the fire will be the upholstery inside your car burning from the floor boards. Any questions and I will be glad to help. Link to comment Share on other sites More sharing options...
1clean00 Posted August 27, 2015 Report Share Posted August 27, 2015 did you use the existing flange off the oem downpipe or use a new flange and go from there? If you could do sections with the flange and turn down off the turbo to the flex section you could sell those all day long. Then all you'd need is cat of your choice, or no cat and the rest is up to the end user. Ideally i'd like a v-band connection for the cat that could be swapped with a test pipe. Link to comment Share on other sites More sharing options...
Welditup Posted August 27, 2015 Author Report Share Posted August 27, 2015 1clean00; I used my existing flanges for now but had to bore it out to the max. When I go 3" on my downpipe off the turbo I'll be getting a 3" flange. I was very surprised how much meat is on the stock flanges. If I get some jigs made up I could start selling some. I can use my car fitment test and ship it out. Link to comment Share on other sites More sharing options...
1clean00 Posted August 28, 2015 Report Share Posted August 28, 2015 Here is a vid of my old S40, 250hp pull, 300ftlb. 14T, upsolute tune, 2.5" exhaust, K&N panel, intercooler hard pipes, mbc @ 20psi. AFR's were 12.5's from 4K up through 6,800rpm. https://drive.google.com/file/d/0B_qYxEQue5TPVTdxVHdjdWRjNHM/view?usp=sharing Link to comment Share on other sites More sharing options...
Welditup Posted August 29, 2015 Author Report Share Posted August 29, 2015 Nice, sounds awesome. I wont be hitting the rollers till after winter. Would like to hit those same numbers. Perfect amount of ft lbs to keep your tranny still happy,lol. You ever run it down the 1/4 mile? Link to comment Share on other sites More sharing options...
1clean00 Posted August 30, 2015 Report Share Posted August 30, 2015 I did, best pass was 14.3 at 105mph. I imagine had i taken some load out of the car (stereo equipment), lost the spare tire and aired my tires a bit differently i could have broke 14's. I did remove the drivers side corner light also and ran a feed straight into the airbox. Also maxed the MAF on that pass, spun tires of the line and chased down a Subi Link to comment Share on other sites More sharing options...
Welditup Posted August 30, 2015 Author Report Share Posted August 30, 2015 Yes, I think so too 1clean00. That trap speed is 13sec terrritory. I would be very pleased to hit low 14's. There's a TON of dodge challengers and charger r/t's around here that need the smack down, lol. I was at the track not to long ago and they run mid to low 14's. Obvoiusly a r/t with mods I wouldnt stand a chance. How was your 60' time? Link to comment Share on other sites More sharing options...
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