I'm reasonably pleased with my one-ball, especially for the cost, but I think my muffler is leaking (I haven't gotten under and checked, it just sounds like that), and I would like something a bit different... In an exhaust thread a while back another user suggested that the OP save his money and instead of going with one of the big brands (Milltek, Billy Boat, Remus, etc.) he just get a local shop to whip up a custom one.

What are everyone's thoughts on this - especially those of you who went this way? It really piqued my interest. What would you look for in a shop that could build a custom exhaust line for a Mini? I have a good local shop that specialized in performance BMWs and Minis. Would you suggest I check with them, or go for an exhaust-specific place? If I find a good place, what should I look for in the various components (tubing, muffler(s), tips, etc.)? Any other suggestions are welcome... As are pics - the more the better! - and sound clips.

ps. For what it's worth, I couldn't build a custom line myself. But if I bought an aftermarket item, I would install it myself.

 

No one, really? Maybe I'll just start calling around...

 

I'm interested in this as well. my local exhaust shop did my one ball mod for me for 30 dollars, what a steal! But now im looking at getting 2.5 inch tubing from the header back and routing it just like the one ball but with a slightly louder muffler. I really dont see how this wouldnt be equivalent to some of the much pricier sets available from manufacturers...

 

I would definetly go the custom way (I did). By doing so you can chose exactly what the sound will be and the tubing size.

For the sound you can chose a variety of mufflers or resonators to get exactly what you want.

Another plus with going custom is you can chose the material ... stainless vs normal steel vs titanium

My custom exhaust cost me about 500$ which was cheaper than any high quality exhaust shipped to my house.

Call around to get quotes and then take the plunge

 

That's the kind of response I was looking for... Thanks! I'm still unsure of what type of shop to call. Maybe I'll just call my Mini/BMW specialist and ask them.

 

I went to one of the big shops (I think it was Meineke?) and had them fab up an exhaust from scratch. They used 2.5" tubing all the way front the front to a smallish muffler at the rear-left of the car (where the factory muffler is), then out to an oval exhaust tip in the factory location. The tip looked essentially like what you see on a Porsche Boxster.

The system was pretty loud, so the installer cut out a straight section of the exhaust tubing a little ways behind the cat and installed a second, tubular-style muffler using flanges so I could switch back and forth between having the second muffler or just a straight length of pipe.

I was happy with it, and the crackling/burbling was sublime. I ended up going back to stock after a few years, though, because even with the second muffler, the droning was bothering me on long interstate drives. But at a total cost of about $300, I feel like I got my money's worth.

 

I built my own. I used 2.5" aluminized, mandrel-bent piping, a 4" Pypes Performance "M80" resonator by the cat, and a Vibrant 2.5" "Ultra Quiet" flow-through resonator with large Magnaflow tips out back. All parts bought through Summit Racing Equipment. I spent $275 before buying the tips, which were $35/each.

The setup is very aggressive. I've had people tell me (mostly gearheads at autocrosses) they love how the exhaust sounds, and I've had others (mostly soccer moms in Escalades) tell me that it was too loud, and that they would call the police.

Pros:
- Noticeable gain in power, butt dyno says around 5-10 whp.
- 20-40 lbs weight loss.
- Goodbye exhaust tips by Budweiser.
- Aggressive tone.
- Cheap, if you buy the right parts from the right vendors and/or scavenge parts.
- Sounds epic on the overrun.

Cons:
- Taking exhaust on/off for fabrication.
- Limited options as far as "backbox" mufflers go; gotta choose something relatively small.
- Can get pricey if you're an idiot like me.
- Need welder (human or otherwise), or 3-4 slip-fit "torq-tite" clamps.
- Loud.
- Loud.
- Everybody thinks you're racing them if downshifting.
- Loud.

In hindsight, I would probably design my system a different way to fit as large a muffler as I can in the back. Methinks I will replace that resonator with a proper Magnaflow. That should quiet things down a bit since it's a bit loud for my taste.

Or, just save myself the trouble and buy the Ireland Engineering exhaust, which I was trying to copy for myself.

 

I’ve had a few custom mandrel bent systems.

Mandrel is the key word you are looking for.
Then it's up to you which muffler/tip to use and the size and kind of the tubing.
The shop well HELP.

Try here, looks like they do pretty good Mandrel bent custom work.

Carline Mufflers
Bay 6 - 727 33 Street N.E.
phone (403) 273-4506
owner/operator Rick Withell

Carline Mufflers
1936 30 Avenue N.E.
phone (403) 291-1951
owner/operator Azim Bhanji

Carline Mufflers
1803 11 Street S.E.
phone (403) 215-0110
owner/operator Eric Skagen

 

Any clips of the sound?

 

Thanks for the suggestions! I'll contact Carline (whom I'm assuming you found out about just by a search, or do you have experience with them?) and see what their suggestions are. I think I'll also contact my Mini shop and see if they can point me toward anyone. Stay tuned...

 

I'll try and oblige that request this weekend; my brother's girlfriend bought him a GoPro2 for his birthday.

 

I think I've decided that going custom would have to beat the cost of an Ireland system... I know, I know: it's not as super-awesome-o as a Milltek or ______. But it's pretty much exactly what I want: simple and inexpensive. I can't really see any reason to carry around two giant mufflers for such a tiny little motor. Once again, stay tuned!

 

Any idea what size mufflers we can fit?

 

Agree with you on the Ireland. From the clips I've heard, the ireland sounds much like a one-ball but deeper. I also like the single muffler design (K.I.S.S).

Keep us posted

 

After looking at the Ireland exhaust I noticed the exit of the exhaust seems to come from the side of the muffler. I haven't been able to find such a muffler and the shortest magnaflows are 13 inches long with the exit being at the back of the muffler. Does anyone know if that will still fit where the old muffler was including the new bends towards the exhaust tips, or is there a recommended muffler for this sort of setup?

 

Try Vibrant exhaust..... they have several different muffler in/out configurations/sizes and street or race applications. I'll be having Sneed's Speed Shop outside Winston-Salem, N.C. fabricate my exhaust system next week. That's what they use on all their race cars.

 

I'll have my home-engineered double louvered glasspack straightback at MOTD if you want to see... it's aggressive but I haven't had an Escalade driver complain yet.

Not that I could hear, anyway...

I'll also be bringing another one to sell, that one's slightly TOO aggressive, but all stainless.

 

MOTD is HUGE this year............ see you there!