Exhaust upgrade - expert advice please

[NitroDann]

It needs to have the same configuration, same number of cats and sensor locations, same number of mufflers etc.

Dann

[Gmi]

Coffee Boss in the right background of that pic of the cars.

Now we know where Matt stole his alias from

~ if concerned about legality, flash tune ecu, 4.1 fgr no legal issues there.

[OurCognitiveSurplus]

On topic: So anyone like to clarify the rules regarding exhaust legalities esp the catalytic converter issue?

My reading of the Commonwealth regs, provided as guidance to the States, is that any exhaust mod which may impact emissions will need a cert. So OEM replacement is fine, but once you're talking about a new arragnment of CATs or maybe even a bigger pipe, you're in trouble.

linky:
http://www.infrastructure.gov.au/roads/ ... _ncop.aspx

Your State may not have adopted the whole NCOP.

1.1 BASIC MODIFICATIONS NOT REQUIRING CERTIFICATION

The following are Basic Modifications that may be performed without certification providing the
modifications are carried out in compliance with the requirements detailed in Clause 2 General
Requirements:

 Fitting a replacement new, used or reconditioned engine;
 Fitting a manufacturer’s optional engine together with any associated components as
supplied by the manufacturer for that same model vehicle;
 Fitting replacement original equipment engine and exhaust components;
 Fitting replacement original equipment, equivalent or better, components that have no
influence on engine performance or emissions (e.g. higher volume oil pump than original);
and
 Fitting equivalent engines with an increase of up to 20% of original power.
In all of the above cases, if the engine is modified, it must be certified under the relevant Code
of Section LA.


1.2 MODIFICATIONS REQUIRING CERTIFICATION UNDER LA CODES
The following is a summary of modifications that may be performed under Section LA:
 Fitting engines greater than 120% of original power and/or engine mass;
 Fitting performance engines;
 Fitting engines from non original equipment sources;
 Installing a supercharger or turbocharger; and
 Modifying the engine and engine components that results in an increase in engine power
of more than 20% and/or affects exhaust emissions.

[Zohxoco]

Thabks OCS.

So that means that 99%+ of all aftermarket exhausts are illegal!

[OurCognitiveSurplus]

I guess I'd argue that my axel-back comes after all emissions control dodats, there's no evidence that the axel-back increases performance and the 'no cert' section says "fitting replacement original equipment, equivalent or better, components".

So in any tiny way that my exhaust is 'better' that is captured by the above.

But yes, any substantial exhaust work is probably in need of a cert.

[Dan]

On topic: So anyone like to clarify the rules regarding exhaust legalities esp the catalytic converter issue? I would still like to know why a replacement header and midpipe with two catalytic converters would be considered "illegal" in Australia? Is it the type of catalytic converter used? Or is it because it is an unknown quantity that hasn't been tested yet officially and thus not an approved mod? What about if I went to a local Aussie specialist exhaust place and got a custom exhaust, would that be legal, or would it need an engineer signoff? These are genuine questions, not trying to stir or anything, I just want to know more.

You've changed the emission equipment so they want to certify it that it still complies to the standard is the jist of the reason.

If you aren't a goose and aren't on your P's you probably will never get defected with a moderately loud exhaust so don't sweat it and if it does happens just change it back to stock.

If you are interested I can give you some insight into the process as I'm going through the process of having my Evo X engineered at the moment so I know a bit about how it's done (I'll just talk about stuff that's relevant to the exhaust):
- Before seeing an engineer you'll need to get your car emissions tested at one of the Emissions Testing Station's in Sydney (Botany and Penrith). They'll test that the Cat's are effective (I put the stock Cat back on and changed the tune for this test).
- You'll also need to get the car weighed at a weighbridge that can print you a report on weight.
- If you changed the headers they will need to have a well made heat shield fitted over them.
- Pretty much any after-market Exhaust is going to go over the DB limit, the noise test will be conducted by the certifying engineer and before testing he is supposed to take out all removable noise suppressors like baffles. you need to speak with the engineer but some are reasonable as long as you tried to keep the noise down they will 'make it pass', if it's some stupid race exhaust then probably not.
- This will almost certainly cost you >$1,000 when all's said and done

My Evo is pretty heavily modified (>300kw at the wheels) which is why I'm doing it, I wouldn't worry about it for a mildly modified car.

[Zohxoco]

OK lots of good info thanks guys.

[Gamefish77]

Thanks for the interesting thread, but I have a few questions again?

I fitted the muffler this morning after it arrive FedEx last night...very professional and Brian was great to deal with particularly given I originally ordered the full system, then requested he just ship the muffler and provide me a refund. Recommend him.

After I fitted it this morning, I went for a very short drive just to test it out.

A couple of questions for you from a non-mechanic.

1. I notice a bit more exhaust smoke from the tail pipes with the new muffler.  Is that normal?  The smoke is whitish grey colour, but I never noticed it prior.
2. The exhaust has a slightly more fume smell to. Smeels a bit burny. Is that normal?
3. Do you get more sound with the baffles bolted in (as it arrived), or with them removed.

The increasinnoise is very minimal, in fact I can hardly notice it at all. A little bit more burble sound, but very minimal and nowhere near as noisy as I anticipated.

Thanks

[myredmx5]

Have you replaced the gaskets?

[Gamefish77]

Have you replaced the gaskets?

I fitted the muffler with the new gasket between the end of the mid pipe and the muffler, yes. The new gasket Came with the muffler, but i did note that on the OEM there wasnt as gasket, or at least none I could see. It was a perforated thin metal gasket with some type of coating over it.

Do you think that could be the smell and smoke? Will it eventually go or likely to stay?

[neilhr]

Thanks for the interesting thread, but I have a few questions again?

I fitted the muffler this morning after it arrive FedEx last night...very professional and Brian was great to deal with particularly given I originally ordered the full system, then requested he just ship the muffler and provide me a refund. Recommend him.

After I fitted it this morning, I went for a very short drive just to test it out.

A couple of questions for you from a non-mechanic.

1. I notice a bit more exhaust smoke from the tail pipes with the new muffler.  Is that normal?  The smoke is whitish grey colour, but I never noticed it prior.
2. The exhaust has a slightly more fume smell to. Smeels a bit burny. Is that normal?
3. Do you get more sound with the baffles bolted in (as it arrived), or with them removed.

The increasinnoise is very minimal, in fact I can hardly notice it at all. A little bit more burble sound, but very minimal and nowhere near as noisy as I anticipated.

Thanks

That's all normal, the muffler has a breaking in period 500km-1000km. The white smoke and smell will go away. The muffler will eventually get louder too.

My baffles work well to take the edge of the sound. I've got a full system, it might be hard to tell with just a muffler

[Gamefish77]

Thanks for the interesting thread, but I have a few questions again?

I fitted the muffler this morning after it arrive FedEx last night...very professional and Brian was great to deal with particularly given I originally ordered the full system, then requested he just ship the muffler and provide me a refund. Recommend him.

After I fitted it this morning, I went for a very short drive just to test it out.

A couple of questions for you from a non-mechanic.

1. I notice a bit more exhaust smoke from the tail pipes with the new muffler.  Is that normal?  The smoke is whitish grey colour, but I never noticed it prior.
2. The exhaust has a slightly more fume smell to. Smeels a bit burny. Is that normal?
3. Do you get more sound with the baffles bolted in (as it arrived), or with them removed.

The increasinnoise is very minimal, in fact I can hardly notice it at all. A little bit more burble sound, but very minimal and nowhere near as noisy as I anticipated.

Thanks

That's all normal, the muffler has a breaking in period 500km-1000km. The white smoke and smell will go away. The muffler will eventually get louder too.

My baffles work well to take the edge of the sound. I've got a full system, it might be hard to tell with just a muffler

Neilhr, thank you. Sounds like the smell and smoke is normal then. Keen for it to go away though.

Mine came with the baffles already in place in the tailpipe. I removed them by undoing ghe bolt and removing from the tailpipe, but could not really hear any noticeable difference between when they were in , and when I took them out. Am I right in assuming the noise should be a bit deeper and louder with them removed?

Might be a silly question, but I have no understanding of these types of things...

[neilhr]

Thanks for the interesting thread, but I have a few questions again?

I fitted the muffler this morning after it arrive FedEx last night...very professional and Brian was great to deal with particularly given I originally ordered the full system, then requested he just ship the muffler and provide me a refund. Recommend him.

After I fitted it this morning, I went for a very short drive just to test it out.

A couple of questions for you from a non-mechanic.

1. I notice a bit more exhaust smoke from the tail pipes with the new muffler.  Is that normal?  The smoke is whitish grey colour, but I never noticed it prior.
2. The exhaust has a slightly more fume smell to. Smeels a bit burny. Is that normal?
3. Do you get more sound with the baffles bolted in (as it arrived), or with them removed.

The increasinnoise is very minimal, in fact I can hardly notice it at all. A little bit more burble sound, but very minimal and nowhere near as noisy as I anticipated.

Thanks

That's all normal, the muffler has a breaking in period 500km-1000km. The white smoke and smell will go away. The muffler will eventually get louder too.

My baffles work well to take the edge of the sound. I've got a full system, it might be hard to tell with just a muffler

Neilhr, thank you. Sounds like the smell and smoke is normal then. Keen for it to go away though.

Mine came with the baffles already in place in the tailpipe. I removed them by undoing ghe bolt and removing from the tailpipe, but could not really hear any noticeable difference between when they were in , and when I took them out. Am I right in assuming the noise should be a bit deeper and louder with them removed?

Might be a silly question, but I have no understanding of these types of things...

No worries, I only know because I went through all this when I got mine
Yeah just keep the baffles removed for now, they aren't useful until you have the headers on there.
The muffler needs to burn off all the oils and other materials inside from the manufacturing process. Long drives will help speed up the break-in because the muffler gets really hot. At a track for example you could break it in very quickly.

You should hear the sound get more throatier as it breaks in

[Gamefish77]

Thanks for the interesting thread, but I have a few questions again?

I fitted the muffler this morning after it arrive FedEx last night...very professional and Brian was great to deal with particularly given I originally ordered the full system, then requested he just ship the muffler and provide me a refund. Recommend him.

After I fitted it this morning, I went for a very short drive just to test it out.

A couple of questions for you from a non-mechanic.

1. I notice a bit more exhaust smoke from the tail pipes with the new muffler.  Is that normal?  The smoke is whitish grey colour, but I never noticed it prior.
2. The exhaust has a slightly more fume smell to. Smeels a bit burny. Is that normal?
3. Do you get more sound with the baffles bolted in (as it arrived), or with them removed.

The increasinnoise is very minimal, in fact I can hardly notice it at all. A little bit more burble sound, but very minimal and nowhere near as noisy as I anticipated.

Thanks

That's all normal, the muffler has a breaking in period 500km-1000km. The white smoke and smell will go away. The muffler will eventually get louder too.

My baffles work well to take the edge of the sound. I've got a full system, it might be hard to tell with just a muffler

Neilhr, thank you. Sounds like the smell and smoke is normal then. Keen for it to go away though.

Mine came with the baffles already in place in the tailpipe. I removed them by undoing ghe bolt and removing from the tailpipe, but could not really hear any noticeable difference between when they were in , and when I took them out. Am I right in assuming the noise should be a bit deeper and louder with them removed?

Might be a silly question, but I have no understanding of these types of things...

No worries, I only know because I went through all this when I got mine
Yeah just keep the baffles removed for now, they aren't useful until you have the headers on there.
The muffler needs to burn off all the oils and other materials inside from the manufacturing process. Long drives will help speed up the break-in because the muffler gets really hot. At a track for example you could break it in very quickly.

You should hear the sound get more throatier as it breaks in

Thanks you very much, excellent forum the insights are very valuable to a new owner.

[Zohxoco]

1. I notice a bit more exhaust smoke from the tail pipes with the new muffler.  Is that normal?  The smoke is whitish grey colour, but I never noticed it prior.
2. The exhaust has a slightly more fume smell to. Smeels a bit burny. Is that normal?

The smell that I got was like burning wax. It went away very quickly (less than 400km). Never saw any smoke. Let us know if it doesn't go away.

The increasinnoise is very minimal, in fact I can hardly notice it at all. A little bit more burble sound, but very minimal and nowhere near as noisy as I anticipated.

You need the header