Drivetrain Poor Mans JCW Exhaust (DIY)

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Old Jan 10, 2020 | 12:36 PM
  #1  
pinky_chi's Avatar
pinky_chi
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From: San Diego, CA
Poor Mans JCW Exhaust (DIY)

Used my oem muffler to create my own "poor mans JCW exhaust". Basically cut off one of the tips on the oem muffler, welded on a ebay exhaust flap right before the muffler and ran a straight pipe through bypassing the muffler.

Cost: $160
Time: ~6-10 hours? (didn't really keep track)

The sound isn't quite what I imagined. The quiet mode is a bit louder than stock while the loud mode is more quiet than a straight through pipe. I think if I were to close the oem muffler instead of leaving it open it should quiet down the 'quiet mode' to oem levels. Along with that maybe extend the 2.5" straight through pipe all the way to the tip so that the baffled tip doesnt muffle the loud mode as much that should make the loud more louder. For now though I'm happy with the result as my previous straight pipe was too loud.

Previous exahust. Straight through pipe, or muffler cutout.


OEM muffler cut open right in between the two tips.



Basic mock up of the layout.


All cut and welded up. I cut off the oem tip as well so I could add a short 2.5" fake tip. This way I could buy a set of 3.5 to 2.5 or 4 to 2.5" exhaust tips.


Not shown here but I ended up extending that second narrow exhaust tube coming out from the muffler to meet the 2.5" straight pass pipe.


With the back piping welded on.


All mounted. Had to bang the center exhaust hanger back because the exhaust flap was too big and was hitting it.


With my Autozone 26$ 3.5" tips. I was originally planning on using ECS tuning 4.0" tips but that would've doubled the cost of this project so holding off for now. These are also screw on so I can upgrade anytime I want. For now though I do like the oem look of these tips.

Following Remus' exhaust installation I ran the cable through the flat tire tool compartment into the cabin. For now its running off the 12v cigarette lighter but I'll hard wire that into the fuse box soon.


 
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Old Jan 11, 2020 | 08:07 AM
  #2  
mcaanda's Avatar
mcaanda
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From: SW Colorado
Pretty dang cool and really not into it for significant $.
 
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Old Jan 12, 2020 | 10:25 AM
  #3  
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CarFreak427
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From: Merriam, KS
That's super cool. Need sound clips.
 
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Old Jan 12, 2020 | 05:51 PM
  #4  
Bald Headed Traveler's Avatar
Bald Headed Traveler
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With the prior puffier delete did you only delete the muffler? Other wise stock exhaust? And you felt it was too loud? Thinking of just deleting my muffler on my 2019 F57 .
 
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Old Jan 13, 2020 | 11:04 AM
  #5  
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pinky_chi
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Originally Posted by Bald Headed Traveler
With the prior puffier delete did you only delete the muffler? Other wise stock exhaust? And you felt it was too loud? Thinking of just deleting my muffler on my 2019 F57 .
Yea completely stock exhaust except the axle back muffler. Startup and acceleration were definitely loud. You could also hear the exhaust during highway cruising and if the rear seats were down then there was a tiny drone in the cabin. The sound however was really nice, a deep low growl and the pops were much louder.

Sound clip of old muffler cutout:
 

Last edited by pinky_chi; Jan 13, 2020 at 11:28 AM.
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