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

Here is some info from Cobb Tuning for exhaust design I digested as part of my DIY.

CobbTuning.com - Exhaust Design

 

Yeah.....
I considered an Isosceles Trapezium (the Brit description was for the Mini heritage, and for you Agro), that would mimic the cutout in the bumper, and I may consider it as a later design. The whole setup will be fully interchangeable. Including the rear muffler. However designing Isosceles Trapezium muffler baffles although not impossible would be much more time consuming for me. So for now I sticking with the more MINI appropriate twin exhaust outlets. But thanks for the suggestion Mark

 

Nah...
That's what the Brits call an Isosceles Trapezoid. I thought I would keep it in Mini-ease.

 

Here's a Greek downpipe made by Akrapovic, in SS with a cat. 490 Euro's about $670.00 US + shipping. Wonder how it handles CEL's. Read somewhere where Riss Racing went under. Thought their DP looked looked good. This looks well made.

http://www.akrapovic.com/typo3conf/ext/user_products/mod1/uploads/products/evolution_exhaust_system_for_the_mini_cooper_s_r56_and_cooper_s_cabrio_r57_/mini_cooper_s_en_web.pdf

 

Something along this line?

[ame]http://i540.photobucket.com/albums/gg348/DedRokGallery/047e6ff4.jpg[/ame]

 

Just a little update on my progress today...

With acknowledgement to Keith Huevo, I'm going with the simpler bolt up flanges, but three bolts instead of two. Better spreading of the clamping forces. And with respect to leaks (David in Germany), I have a little something up my sleeve so to speak. No, not gaskets. I'll share my idea for this when I start to build.

Had a little spare time today and whipped out a quickie Cad drawing for my exhaust flanges. These puppies will be 3/8" thick T304 SS. I should be able to do this for less than $20.00 each.

Here's a pic of the flange drawing.

 

Just now received an 8' length of 2-1/2" OD perforated 16 Gage T304 SS tubing. This will be chopped up and made into a removable resonator that will also be rebuildable. The remaining length will become the tunable rebuildable rear muffler.



As viewed by the exhaust gasses.

 

Thanks Keith and Adam for the input. I completely overlooked the accessibility issue of getting to the third fastener up inside the aluminum heat shield tunnel area. Good catch.

I'd like to make it as easy as possible to do change outs of the center resonator without dropping the entire exhaust.
Made a quick change to the flange drawing this morning.

 

Well that's super.....

Just a quick clarification on my part.

I have no intention of making and selling these exhausts and competing with the vendors on this forum. I intend to be completely transparent in the construction methods, and sources for the raw materials. I hope it's going to almost be like you guy's are here helping me from you living room with suggestions and recommendations.

I will weigh both the factory and this exhaust for comparisons. I have no intention of doing any form of dyno or flow testing. If I end up making something that is lighter than the stock factory JCW exhaust and perhaps sounds a little better, that can be acoustically tuned and easily rebuilt then I'll be satisfied. I will try and make a drive by sound clip of both systems for comparison (this is hard to do well, in my opinion).

If anyone else wants to make one, there should be all the info on this thread to do so.

Anyway, that the plan........