So, it's finally happening after all this time... I'm getting the exhaust done. My goal is to be the loudest Countryman on here (joking, but it will end up being the truth).

In an effort to not make the system completely unforgiving (I was originally going to straight-pipe the entire exhaust), I've purchased an electronic cutout and stainless adapter. I feel that this is an excellent compromise, as I'll be able to still have the quiet when I need it. Read: wife and/or police.

So, I'm going to ask you good people to chime in with your comments on where you would place your cutout. I've made a diagram using threar's photograph from his installation. This will illustrate where we can put the cutout, chop stuff out, etc.



I'll make it even simpler and give you the numbered options!

First, the 2nd cat is leaving regardless. It's not really a necessary cat, has nothing to do with emissions, and is removed on the JCW exhaust and other aftermarket exhausts.

1) This removes the 2nd cat and replaces it directly with the cutout. This is the simplest option, requires one basic cut, and it's over. The cutout sound will literally be like having an open downpipe right under the driver.

2) Remove both the 2nd cat and the resonator, and replace with a cutout. This keeps the cutout sound the same, but changes the sound of the muffler-based system to having no more resonator. This may be preferred to get a sporty sound even when the cutout is closed. Also, the cutout can be relocated anywhere along the pipe (including much farther back). However, I don't know how the system would sound with no resonator - some say that it's pure drone and unenjoyable, but that's on the R56. Who knows on the R60...

3) This is a much quieter option. This removes the 2nd cat, keeps the resonator, and installs the cutout right before the muffler. The cutout sound will still have a resonator in there, but will bypass the muffler.

So, guys... check these out, and let me know what you would do! It will make us all brainstorm, at least.

 

I would go with #3 I think it would be too bad sounding with all the bits cut out.

 

+1 on #3

 

I can't decide between #1 and #3. I like the simplicity of #1, but I suspect #3 would end up sounding better.

 

3, but if you can run it out the back to one of the existing tail pipes, it would be coolest. i.e.: left tailpipe comes out of muffler, right one comes from cutout.

 

I agree - the simplicity of #1 makes it extremely tempting! The issue that has me questioning that is the dumping right under the driver. That could be hellish.

 

Alright... judging from your responses, I've generated option #4.

And while I've already ordered the Magnaflow part, don't let that stop you from honestly replying!

4) Remove 2nd cat, remove resonator, replace with Magnaflow #10436. Install cutout immediately before rear muffler.



Cutout closed: Magnaflow -> Stock Muffler
Cutout Open: Magnaflow -> Cutout

The best part of this Magnaflow piece is the 28" length, which allows the 2nd cat and resonator to be deleted and replaced with this single piece. No additional pipe or fabrication is needed. If you can find a sawzall and a welder (or any shop with both), you're talking $40-50 for the whole shebang (plus the cost of the Magnaflow, and cutout in my case).

The benefits of this setup include a lower tone (just as quiet) with the cutout closed, and a Magnaflow rumble with the coutout open. I think it's the best of both worlds. Feel free to berate me for the decision. Nothing is final until it's welded (and even then...)!

Total cost for the setup will be: $72.76 (Magnaflow) + $175.00 (Cutout) + $40 (Labor) = Under $290 for what is essentially 2 exhaust modes, and it's all still stainless. I have an issue with shops using aluminized - you can't find shops here in Missouri that use stainless pipe...

I forgot to add in the cost of the DiMisa black tips, but that's really just a style thing. -- Still cheaper than even the Borla catback that's really just a muffler swap.

 

I like the last option with the Magnaflow. Looking at the width of the cat and resonator there seems to be enough room to get a high flow oval shaped muffler in there with opposite end but same side entry/exit.

Or add another shorter muffler like you have shown just before the turn up to the stock muffler and delete the stock muffler and just have a shop bend some pipe and attach your tips.

Lots of options but with the muffler so close to the front your bound to have drone, but I don't think your too concerned about that.

 

I dont know why you would do this. You will lose back pressure on the stock turbo and tune.. and lose power.

Just seems like useless noise.. why not get a properly tuned exhausted for your car that will sound and perform properly..

Just my .02.. you do drive a MINI lets keep it classy.

 

Well, let's look at this another way:

The 2nd cat/pre-cat/resonator removal is done very commonly on the R56. What difference would it make on the R60 since it shares the N18? In fact, I'm adding back in a Magnaflow to quiet it back down.

Second, the backpressure is a non-issue for the most part, especially since the cutout will be placed at the rear of the system. Also, on a turbo vehicle, that's pretty much a moot point since the pressure is kept in the system. Perhaps I should reiterate - this is an electric cutout that is not for everyday use. The everyday exhaust system will include a large Magnaflow resonator and the factory muffler.

I'm hoping for constructive comments for sure, but I'm not exactly sure how this install is not "classy". In fact, I'd say that these options are very well thought out. There is no such thing as a "properly tuned exhaust" for the R60. They all (as of right now) remove the 2nd cat and resonator, then remove the factory muffler.

 

I just think the cut out is something I would see on a ricer srt-4.. or some honda. Why do you need a cutout on an R60??

Just to make useless noise and draw attention to you.. i dont know. my .02..

I just dont see the gains to do it.

 

Ah, fair point! That's certainly not the idea I had. I despise the 'ricer' mentality, nor would I use it for that purpose.

I'd like the ability to keep my car extremely quiet (I live in an upscale community, and I'd like to keep things quiet in here) for my neighbors, my wife, child, etc.

I also enjoy hearing my motor stretch when I'm on the highway or having fun out by myself. That's the freedom I'll have by installing the electric cutout - silence or loud in a button press.

I realized that with the first options I posted, it was just an obscene amount of noise for no reason. I'm not a teenager anymore (though that would be nice), so that's not going to work for me.

This compromise makes both methods (full muffler and muffled cutout) very sporty, and in my opinion, a 'classy' way to explore both sides of the coin. On an R60, there are two sides - the R56 is a sports car... the R60 just wants to be at times!

 

Are you on stock DP?

In all honesty if you want "loud" with "quiet" I would get a catless DP and tune. Now I know tuning is not out yet I believe but when it is.

I have a Riss Racing Catless DP for my R56 (used $200 shipped). And when I am just cruising it very quite and when I get on it.. it screams even with the stock catback.

Actually a lot of people are surprised by the sound of it.

But thats my .02.. the stock cat in the DP really does a great job of quieting down the exhaust..

 

Yep - it's on the list for when the ECM code is unlocked and tunable!

I looked into buying an R56 DP, but the ETK shows a difference in size. The other problem here is that I don't like messing with cats. In Saint Louis, we have onramp sniffers for emissions. I got popped in my GTO years ago for that.

That being said, when something comes available, I'll probably jump on it for all that extra HP/TQ (around 15-20 on the R56, from what I've read).

 

Yeah, I love my DP. I cant justify a cat-back since there are almost 0 performance gains to them on stock turbo even tuned.

Once you can get a tune.. that catless DP will do a lot as far as making the car loud. I dont know if they are different in length or not but diameter it should be the same. Mine is a 2.5" Catless DP right now.

Makes great power tuned.

 

You hit the nail on the head. Catbacks are all about noise to begin with, hence this project is really no different. They make 0 difference on our turbos, as we keep pressure recirculated up there (backpressure isn't an issue), and there's certainly no restriction with 2.5" pipe until you start making big power.

Diameter on the DP is the same, length is 2-3" different from the specs here.

Don't tease me about the tuning. I'd kill for it right now.

 

Yeah having a 2.5" Catless DP they say flows as much as the catted 3" exhaust sytems being I have 0 restriction in flow.

Yeah it would be great if you had some tuning. You might be able to make some more power on the cutout.. I know some kids seem to make more power with cutouts.. but thats like big turbo cars generally..

 

Goodies came today: (E-Cutout not pictured, testing it now)

 

Ending this thread. Launching another exhaust install thread for the sake of user searching in the future.