Easiest exhaust replacement

[texaselite]

1991 Elan...live in Texas. Pretty sure my cat has been deteriorating inside (have been able to fish out some corroded metal pieces in back muffler).

I would like to replace the entire system, but really don't want to mess with any porting or over-boost issues. If possible, a 1:1 replacement would be ideal...not looking to free up any HP with stiffy, etc. Love the stock sound of the exhaust.

Can someone tell me where to order this full system from? If it's stainless that's great, if not, I will love with it. Car is barely driven (40k miles after 20+ years).

Thanks!

[texaselite]

Anyone?

Tempted to just get the 2.25" Piper system. Just don't know if I also need the PCE, if I need the additional silencer or sports cat (can someone explain these 3)? I assume I will run into some potential boost creep, but I guess I will live with it? If I need to get some extra modifications done to make things "right" can someone explain what I need to tell my mechanic (as far as wastegate porting and other changes). Do I need to buy a chip also?

Any info is appreciated.

[JIMBO]

Anyone?

Tempted to just get the 2.25" Piper system. Just don't know if I also need the PCE, if I need the additional silencer or sports cat (can someone explain these 3)? I assume I will run into some potential boost creep, but I guess I will live with it? If I need to get some extra modifications done to make things "right" can someone explain what I need to tell my mechanic (as far as wastegate porting and other changes). Do I need to buy a chip also?

Any info is appreciated.

Project creep alreadt

[texaselite]

I am usually on the other end of trying to avoid project creep, but if someone can provide solid answers, can get the M100 back on the roads. Been idle since Error 41. Bought the CAS to replace and want to go ahead and do the exhaust at the same time.

[rip]

If you are in the US, then I guess you will need to keep your cat? If so, the Sportcat Piper would be the one to go for.
Do you know what your pass levels are for your emissions test?

We in the UK don't have cats on our SE's which is why the options are available. I don't think Piper offer a system with cat & 2 silencers.
The systems fit to your existing pre-cat. The pre-cat heats exhaust gases to help the cat work better, so assuming you still have a cat, you don't really want to replace your pre-cat with a pre-cat eliminator. A PCE would also allow exhaust to flow more smoothly which will increase your chances of overboost.
Mountain chips give you more boost & therefore more power. They raise overboost level by such a small margin that it will be very unlikely to make a difference. If you are happy with your current performance, then leave your chip alone.

I don't get overboost with my 2.25" piper with 2nd silencer. I may do if I took my Elan on track, but this is something I do not currently plan to do. I would expect a pre-cat & cat will be more restrictive than what I have so I doubt overboost will be an issue to you.

[bobbrown]

Anyone?

Tempted to just get the 2.25" Piper system. Just don't know if I also need the PCE, if I need the additional silencer or sports cat (can someone explain these 3)? I assume I will run into some potential boost creep, but I guess I will live with it? If I need to get some extra modifications done to make things "right" can someone explain what I need to tell my mechanic (as far as wastegate porting and other changes). Do I need to buy a chip also?

Any info is appreciated.

Firstly as you are in the USA would it not be more economical to get a local muffler shop to make an exhaust up? Magnaflow springs to mind and they do make all the parts needed in to make up a system but would need some one with a welder ideally TIG, muffler shop.
I am not sure what the shipping costs are likely to be as although not that heavy an exhaust system can be bulky but very rough guide may be something in the region of $650.00 for the exhaust shipped to the USA.
Making up a new exhaust is not rocket science as they will have the original to copy, just increasing the pipe diameter to 2.25" or 2.5”.

I’ve just modified mine to add in a center box as it was a little loud, probably comes from fitting a turbo exhaust (std) to a NA car but was easy enough with the aid of friends ramp and a my TIG welder.

As for your other questions;
The main consideration is going to be boost creep, if you went with a system that was 2.5" front to back with the pre cat core removed and the main cat then there is a good chance you would get boost creep, not so likely with a 2.25" system but still possible.
Then there are the emissions/smog tests in your area and I do not know if you need to retain the cat/cats, if you do not need them for tests then you can leave them out.
If you add a center box it will reduce the noise slightly and may well reduce the chances of boost creep.
As far as the PCE is concerned it just gets rid of the large lump of cast iron that is the pre cat, but you could opt for the Knox pipe when they get around to making them for Billy, as that will get rid of the cast exhaust elbow on the outlet of the turbo and the pre cat.
Boost creep is a situation where the exhaust gases can not be controlled by the waste gate as the larger diameter reduces the back pressure on the exhaust system to over come this problem the waste gate need it's diameter enlarged to 20mm which then allows it to flow more gas away form the turbo as you approach max boost and does not let it get so high that you get fuel cut off. The chips also move the fuel cut point to a higher figure but not by that much but it does reduce the chances of getting fuel cut off.

Bob

[tigerdog]

Houston should have several reputable exhaust shops around. Assuming your downpipe is OK, the system isn't all that complicated and any reputable bender should be able to do a good job. My car wears a 2.5" exhaust with a Magnaflow hi-performance cat and stainless exhaust and sounds really great.

Just be sure whoever works on it realizes the fuel lines are plastic and run along the same tunnel as the exhaust.

[texaselite]

Thanks guys...

Looks like it's going to cost me pretty to ship that system (w/SportsCat) to US...$836

I have contacted my mechanic to see if he has any contacts for a custom build.

I have noticed some corroded metal pieces in the muffler -- not sure if they are pieces of the cat that have flaked off, or just baffles in the back muffler that are disintegrating. Would any muffler shop be able to handle replacing the entire system including the catalytic converter if necessary?

Is the stock exhaust 2" or 2.25"? I have no intention of going up to 2.5".

[bobbrown]

I would expect any custom muffler shop worth its salt capable of replicating the standard system, I know Magnaflow can supply the boxes the rest is straight forward.
The original cat is a ceramic honey comb so the metal you see inside the rear muffler is probably baffles not the cat core.
The standard system is 2" which is one reason there is some improvements in higher end performance when you go to 2.25" or 2.5", interestingly the increase in size is actually 27% and 56% respectively

Bob

[texaselite]

I would expect any custom muffler shop worth its salt capable of replicating the standard system, I know Magnaflow can supply the boxes the rest is straight forward.
The original cat is a ceramic honey comb so the metal you see inside the rear muffler is probably baffles not the cat core.
The standard system is 2" which is one reason there is some improvements in higher end performance when you go to 2.25" or 2.5", interestingly the increase in size is actually 27% and 56% respectively

Bob

Thanks for the reply...on that note...any reason to keep the new setup at 2" to avoid any possible boost creep? Don't really think wastegate porting + chip is something I want to mess with, but if sizing up to 2.25" will have limited downside, might as well take the increase in performance. Car is being driven fairly leisurely, so not sure boost creep is something I should fear.

[steve matthews]

Go for it

Take the bait

We all did and are glad for it.

Steve -w- 2.25 exhaust

[texaselite]

Go for it

Take the bait

We all did and are glad for it.

Steve -w- 2.25 exhaust

So just go for the 2.25 custom build and don't worry about the porting/chip? That is what I am leaning towards.

[bobbrown]

I would say go for a 2.25 system as it is easier to add a bit of back pressure into an exhaust system than try to get rid of it.

[tigerdog]

Thanks for the reply...on that note...any reason to keep the new setup at 2" to avoid any possible boost creep? Don't really think wastegate porting + chip is something I want to mess with, but if sizing up to 2.25" will have limited downside, might as well take the increase in performance. Car is being driven fairly leisurely, so not sure boost creep is something I should fear.

I would think 2.25" should let you spool a little more quickly and still be safe from boost creep, especially if you intend to keep the catalyst. And if you mostly keep your foot out of it, boost creep won't be a problem anyway. It only happens when you plant your foot and peg the boost needle long enough for pressure to build in excess of what the wastegate can vent. Magnaflow's 91000 series fits nicely where the stock cat sits. 91005 is the 2.25", 91004 the 2" version. They also have a complete line of stainless silencers with tips, any number of which would do the job. Here's the one Smaug wears.