Drivetrain (Cooper S) MINI Cooper S (R56) intakes, exhausts, pulleys, headers, throttle bodies, and any other modifications to the Cooper S drivetrain.

Drivetrain R56 MCS stock exhaust mods?

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Old Mar 30, 2025 | 08:03 AM
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R56 MCS stock exhaust mods?

I guess this is the place to talk about modding my stock exhaust? I got the Milltek sport cat. I have a good buddy who is master welder so no cost to me there. Do I cut out one of the resonanators? I’d like some minor performances gains but I don’t like super loud. These free repairs will spare me the cost of an expensive aftermarket upgrade. Thanks in advance.
 
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Old Mar 31, 2025 | 07:23 AM
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Bump and bumps????
 
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Old Mar 31, 2025 | 08:41 AM
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I think you can do basically whatever you want and it still sounds decent until you mess with the rear muffler, then it gets too loud.

Mine came with stock catted downpipe, straight piped midsection, and some aftermarket rear muffler and it was far too loud. I added a vibrant ultraquiet resonator in the mid section and some Kilmat sound deadening on the trunk floor. It improved, but was still loud enough that you'd get a headache/ears ringing after a few minutes on the highway due to the drone.
 
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Old Mar 31, 2025 | 07:16 PM
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Originally Posted by Northern
I think you can do basically whatever you want and it still sounds decent until you mess with the rear muffler, then it gets too loud.

Mine came with stock catted downpipe, straight piped midsection, and some aftermarket rear muffler and it was far too loud. I added a vibrant ultraquiet resonator in the mid section and some Kilmat sound deadening on the trunk floor. It improved, but was still loud enough that you'd get a headache/ears ringing after a few minutes on the highway due to the drone.
I appreciate the thoughts here. TY. I have no plans to remove the rear muffler, but I’d like to hear more about this resonator. What size? Link? The stock exhaust mid pipe has 2 resonators I think? Maybe I just need one that is 8-10 inches with good airflow?
 
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Old Apr 1, 2025 | 04:01 AM
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If you don't want it loud, don't remove any resonators. Also, the stock exhaust has two cats, one resonator, and a muffler. The OEM muffler can be a bottle neck. Add the JCW muffler, if you can find one. You can remove the second cat and resonator, and add in a larger and longer resonator. Do not straight pipe it, or it will be loud. The Miltek sport cat will help keep some noise in check.
 
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Old Apr 1, 2025 | 06:58 AM
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Originally Posted by njaremka
If you don't want it loud, don't remove any resonators. Also, the stock exhaust has two cats, one resonator, and a muffler. The OEM muffler can be a bottle neck. Add the JCW muffler, if you can find one. You can remove the second cat and resonator, and add in a larger and longer resonator. Do not straight pipe it, or it will be loud. The Miltek sport cat will help keep some noise in check.
another helpful post, many thanks! no straight pipes I’m going to modify what came with the car taking advantage of free professional welding.

I’m going to go get a picture of my stock MCS exhaust and post it so I can follow along better lol.

so I’ve got the Milltek sport cat downpipe. That’s one cat.

then once we get to the mid pipe I guess it’s called, we have:

- 2nd cat right after downpipe
- 1st resonator not sure the length
- 1st muffler

Upgrades as proposed:

- remove 2nd cat
- remove 1st stock resonator, replace with aftermarket performance larger longer resonator - got a link to something in mind????
- remove stock MCS muffler, replace with JCW muffler

profit, win???
 
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Old Apr 2, 2025 | 05:59 AM
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Originally Posted by pkgmSu2000
another helpful post, many thanks! no straight pipes I’m going to modify what came with the car taking advantage of free professional welding.

I’m going to go get a picture of my stock MCS exhaust and post it so I can follow along better lol.

so I’ve got the Milltek sport cat downpipe. That’s one cat.

then once we get to the mid pipe I guess it’s called, we have:

- 2nd cat right after downpipe
- 1st resonator not sure the length
- 1st muffler

Upgrades as proposed:

- remove 2nd cat
- remove 1st stock resonator, replace with aftermarket performance larger longer resonator - got a link to something in mind????
- remove stock MCS muffler, replace with JCW muffler

profit, win???
Sounds like you get it.

For resonator, look for a Magnaflow 10435. This should be a 4" round x 22" long with 2-1/4" inlet / outlet. Should go right onto the OEM exhaust pipe, and be long enough to replace the cat and resonator. Being as long or longer than the OEM cat and resonator should also keep it quiet, too.
 
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Old Apr 2, 2025 | 09:27 AM
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I have a decat downpipe w/ a stock JCW Exhaust. It's pretty loud on the outside with the stock resonator and rear muffler (but no drone, which is a blessing). Its about 80ish dB in the inside on the highway? Outside is about 80ish Db on Idle, and on WOT it gets pretty damn loud (90ish+ dB).

With that said, I highly recommend Vibrant Performance for Muffler and Resonator.

Street Power Muffler, and Ultra Quiet Resonator is always a great combo! or if you find a clean JCW Muffler I'd pair it with a UltraQuiet Resonator from Vibrant Performance.

Not to poke at @njaremka, but.. magnaflow be cheap and not great quality. I'd take Vibrant Performance any day over Magnflow.

Heck - I built a custom exhaust with everything in there catalog for one of my cars, and I've put about 15k miles on it? It's taken a ton of abuse (from massive flames, and pops) and its holding up amazing.

That's my two cents.
 
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Old Apr 2, 2025 | 10:16 AM
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No offense taken. I agree that the Magnaflow OEM replacement stuff is pretty crappy, but their performance line-up is much better. I've had a few Magnaflow performance exhausts on previous cars and they all out lasted the cars. On the flip side, I've had some OEM Magnaflow replacement products that didn't last 2 years before NEEDING to be replaced.
 
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Old Apr 3, 2025 | 07:19 AM
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Many more thanks for the tips y’all :-)
im putting together a plan this week
 
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