2nd Gen JCW Most liked posts in thread: R56 JCW - Build Thread - New Set Of Pipes

So now for some quick and dirty mockups for the style guys.

Here is a quickie with the 4" tubing (outside will be polished on the final version). The center tube would be extended flush with the 4" tube and the baffle plate 1/2" inset. This would be the square cut end (David)



OK, same thing but the center tube is flush with the baffle plate.



I'm starting to think 4" is just too big. There would be two of these cannons next to each other with about a 1/4" spacing.

 

Yeah, I read where 3" is just for bragging rights and the only thing it does is add unnecessary weight. I figured I was pretty safe in only bumping it from 58mm to 63.5mm. That way when the new (future) downpipe goes on that should flow better, the 2-1/2" shouldn't hinder it.
The point is I want to maintain the exhaust temperature and flow rate. And going too big defeats that purpose.

 

Ok, for the style guys....
I made a 1:1 paper template with the 4" tubes and 1/4" space.



Sorry about the poor lighting...
Here is the template centered over the bumper cutout. If I remember, there is about 3/8"gap on the left and right side and about a 1/4 space at the top.



There should be enough clearance where the muffler won't hit the bumper and cause a cabin vibration and still allow some movement of the rubber hanger grommets.

Sooooo, is 4" too big or should I go for 3-1/2"? If I go smaller on the muffler tubing it'll reduce the muffler chamber size and that will reduce my ability of adjusting the sound.

 

I had to look closely to what you said, I definitely don't want it to look "RICER". I see too many Honda's running around town with those fart cannons drooping off the back of their bumper. Sticking with the MINI looking tips but just bigger to fill out the opening.

 

Good point Adam....

The neat thing about the muffler design that I'm going to build will have two removable / rebuild-able / tunable cores. So the shell (4" tubing) would remain in place and the baffle cores would be the removable parts. These cores should take no more than a few minutes to slide out of the muffles tubes without needing to get under the vehicle. I could even put separate designs on each opposite baffle core end. They could both be flipped, and have the small extensions visible or flip them both and have the flush surfaces visible.

Chuck

 

David...
I'm thinking the Supertrap muffler used a series of stacked discs packs. Mine would operate more like a silencer for a firearm with a straight through exhaust.

Chuck

 

Keith.....
You would be the closest winner....

That and something similar along this line as the sleeve that would slip inside the 4" body. You can envision how easy they would be to remove and make baffle changes.

Roadhouse 2.5in. Performance Core Exhaust Insert - Cruiser Motorcycle - Motorcycle Superstore