R56 JCW - Build Thread - New Set Of Pipes

**Metalman** · 01-19-2011, 11:52 AM

OK.....
Here goes...
I'm starting my own thread on my journey making a custom SS catback exhaust. Feel free to give me your thoughts. Especially from some of the members on M/A that have a sense of what would look good from the rear bumper. I'm sticking with the dual tip for now.

It's always good to have a list of objectives, So here is my initial check list;
Needs to attach to the the factory downpipe with the factory clamp.
Will include a SS flex joint.
Will hang from all of the same factory hangers.
Will be made from 2-1/2" OD (63.5mm) T304 SS tubing (factory JCW measures at 2.290" (58mm).
Will have a center section with an easily removable resonator / straight pipe with "V" band clamps.
The resonator will be able to be repacked with high temperature ceramic insulation or scrabble.
The rear muffler will have rebuild-able cores and some acoustical tuning ability (all without needing to be removed from the vehicle).

Here is a shot of the factory JCW exhaust tips. They kind of look a little lost don't they?

**k-huevo** · 01-19-2011, 12:47 PM

I counsel against V-band clamps, R&R is easier with two hole flanges. I would take an extra step and replace the factory flange on the downpipe with a two hole; the OE gasket doesn't seal, and the clamp is a hassle to work with.

I don't think JCW tips are unattractive, it's the standard bumper cover that lacks flair.

**jbewley** · 01-19-2011, 12:55 PM

Quote:

Originally Posted by Metalman

OK.....
Here goes...
I'm starting my own thread on my journey making a custom SS catback exhaust. Feel free to give me your thoughts. Especially from some of the members on M/A that have a sense of what would look good from the rear bumper. I'm sticking with the dual tip for now.

It's always good to have a list of objectives, So here is my initial check list;
Needs to attach to the the factory downpipe with the factory clamp.
Will include a SS flex joint.
Will hang from all of the same factory hangers.
Will be made from 2-1/2" OD (63.5mm) T304 SS tubing (factory JCW measures at 2.290" (58mm).
Will have a center section with an easily removable resonator / straight pipe with "V" band clamps.
The resonator will be able to be repacked with high temperature ceramic insulation or scrabble.
The rear muffler will have rebuild-able cores and some acoustical tuning ability (all without needing to be removed from the vehicle).

Here is a shot of the factory JCW exhaust tips. They kind of look a little lost don't they?

I thought you said business was jumping at your shop and you were up to your ears in work.

Jim

**Metalman** · 01-19-2011, 01:06 PM

Quote:

Originally Posted by k-huevo

I counsel against V-band clamps, R&R is easier with two hole flanges. I would take an extra step and replace the factory flange on the downpipe with a two hole; the OE gasket doesn't seal, and the clamp is a hassle to work with.

I don't think JCW tips are unattractive, it's the standard bumper cover that lacks flair.

Thanks Keith, Good suggestions....

I'll go with you're suggestion on changing the V-band clamps to two hole flanges.

For now, I'm going to stick with factory flange (warranty reasons). I plan to machine a tapered flange to mirror the downpipe flare dimensions. At a later date I can always change it out with something that works better. I may even come up with a split flange with two holes that would eliminate the OEM clamp, yet still preserve the OEM downpipe.

**Metalman** · 01-19-2011, 01:08 PM

Quote:

Originally Posted by jbewley

I thought you said business was jumping at your shop and you were up to your ears in work.

Jim

It is jumping.

This gets done on my time after the shop closes for the evening and on the weekends.

**Metalman** · 01-19-2011, 01:54 PM

Here's a quick auto cad drawing of the rear view through the twin mufflers. I'll do a quick and dirty cut-out and hold it over the factory tips. I'll snap a pic tonight so you guys can give your impression of 4" outlets. I could also do 3-1/2" outlets but I'm trying the keep the muffler chambers as large as I can to be able to let the sound (gasses expand) in the rear baffles.

iwashmycar · 01-19-2011, 02:26 PM

Im sure its going to look amazing. 4" is biiiiig, but It all depends on the fit and finish too.

On the Stratmosphere i had, the tips were only 3.5 i think, and they looked HUUUGE, but they also stuck out some.

**jbewley** · 01-19-2011, 02:30 PM

Quote:

Originally Posted by Metalman

It is jumping.

This gets done on my time after the shop closes for the evening and on the weekends.

Wish I had the tools, shop and skills you do MM. Why do you want to keep the OEM flange if you are changing the set up? Won't that effect eh warranty regardless. Just asking.

Jim

**Metalman** · 01-19-2011, 03:09 PM

Quote:

Originally Posted by jbewley

Wish I had the tools, shop and skills you do MM. Why do you want to keep the OEM flange if you are changing the set up? Won't that effect eh warranty regardless. Just asking.

Jim

Easy on easy off.... backward compatible.....

Stock OEM JCW would get stored here in the shop with only 6-7K miles on it. Someday I may sell the MINI, the original exhaust would go back on.

Chuck

**Metalman** · 01-19-2011, 03:43 PM

Quote:

Originally Posted by iwashmycar

Im sure its going to look amazing. 4" is biiiiig, but It all depends on the fit and finish too.

On the Stratmosphere i had, the tips were only 3.5 i think, and they looked HUUUGE, but they also stuck out some.

Sooo..... Adam
Keep them about the same amount of protrusion from the bumper as the stock. Angle cut tips or square cut? This is where I need input from anyone with a bit of styling sense. You will be able to see up inside the tips since the beginning of the baffle will be about a 1/2" back or so.

Thanks

Chuck