Finally had my exhaust taken care of. Back in 3/9/06 I wrote a thread ( http://forums.vwvortex.com/zerothread?id=2491297 ) about doing a custom rear muffler replacement though I didn't get my 5-door until 9/2/06 :laugh: . Thanks to several members, I have discovered that the OEM resonator is a straight-flow unit. The concept was to copy the Neuspeed/Milltek design to replace the rear OEM suitcase muffler. I retained the stock resonator and replaced everything from the resonator back. The OEM rear suitcase muffler has been replaced by a Magnaflow unit with mandrel bends and a Ractive exhaust tip. My project had three goals: 1) Increase flow by replacing the restrictive rear OEM suitcase muffler, 2) Keep sound levels down by not attracting audible attention, and, 3) Keep cost down to a reasonable level.
A quick post to the local NV/UT Forum on the Vortex lead me to SRS Custom Exhaust (thanks anti bling). SRS Custom is run by the Gilbert family and has been in Vegas for over 30 years. They can build anything you desire; as long as it is legal. Their workmanship is top notch as you can see in the pics of the weld and final product. Dave and his brother Gary expertly laid out the system and made those beautiful welds. :thumbup:
The only thing that differs from my system and the "name brand" ones is that my system does not have the nicely polished stainless steel bling. Rust is not a concern here in Vegas.
Performance wise, I am very happy. Sorry no dynos so I have to rely on my butt :laugh: Prior to the rear muffler replacement, I can feel the restriction of flow in the upper RPMs. Now it is smooth and feels like it breaths much better. Just seems to rev quicker in the higher RPMs. Sound wise, overall pretty pleased since I do not want to attract audible attention. Sound level at idle is stock quiet. When I stomp the throttle the tone is deeper and only slightly louder. The "farts" are definitely louder. Sorry, no sound clips. Just imagine it only slightly deeper and louder than stock. I can always remove the OEM resonator and add a pipe or smaller resonator for a little more noise.
Cost and Parts list:
$ 13.01 Ractive retangular/oval tip (2.75"h x 6" w) from Ebay shipped. BIG
$ 75.00 Magnaflow polished Stainless Steel muffler from Ebay shipped
$130.00 Mandrel bends and installation labor locally.
---------
$218.01 Total
Notes:
I used a small case muffler (14" wide) and thus have a lot of piping compared to the Neuspeed. The reason for the piping is the need to retain the use of the OEM rear muffler hangers. In hindsight, I should have gone with an 18" wide case muffler.
SRS Business card
SRS Store-Look at all of those different sized mandrel bends
The Parts
Mockup
The beautiful welds by Dave and Gary Gilbert
The Tip (still in mockup and is now perfectly aligned)
The finished product :laugh: :beer:
A quick post to the local NV/UT Forum on the Vortex lead me to SRS Custom Exhaust (thanks anti bling). SRS Custom is run by the Gilbert family and has been in Vegas for over 30 years. They can build anything you desire; as long as it is legal. Their workmanship is top notch as you can see in the pics of the weld and final product. Dave and his brother Gary expertly laid out the system and made those beautiful welds. :thumbup:
The only thing that differs from my system and the "name brand" ones is that my system does not have the nicely polished stainless steel bling. Rust is not a concern here in Vegas.
Performance wise, I am very happy. Sorry no dynos so I have to rely on my butt :laugh: Prior to the rear muffler replacement, I can feel the restriction of flow in the upper RPMs. Now it is smooth and feels like it breaths much better. Just seems to rev quicker in the higher RPMs. Sound wise, overall pretty pleased since I do not want to attract audible attention. Sound level at idle is stock quiet. When I stomp the throttle the tone is deeper and only slightly louder. The "farts" are definitely louder. Sorry, no sound clips. Just imagine it only slightly deeper and louder than stock. I can always remove the OEM resonator and add a pipe or smaller resonator for a little more noise.
Cost and Parts list:
$ 13.01 Ractive retangular/oval tip (2.75"h x 6" w) from Ebay shipped. BIG
$ 75.00 Magnaflow polished Stainless Steel muffler from Ebay shipped
$130.00 Mandrel bends and installation labor locally.
---------
$218.01 Total
Notes:
I used a small case muffler (14" wide) and thus have a lot of piping compared to the Neuspeed. The reason for the piping is the need to retain the use of the OEM rear muffler hangers. In hindsight, I should have gone with an 18" wide case muffler.
SRS Business card
SRS Store-Look at all of those different sized mandrel bends
The Parts
Mockup
The beautiful welds by Dave and Gary Gilbert
The Tip (still in mockup and is now perfectly aligned)
The finished product :laugh: :beer:
