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Exhaust Refurbishment - likely costs and components

MattyR

Well-known member
Joined
21 Sep 2015
Messages
796
Hi Chaps,

As the title suggests I'm likely refurbishing my existing (probably original!) exhaust system over the winter. Everything is just so decrepit it's really letting the side down.

I have mind to do a thorough overhaul from the manifold and onwards. I'm not after any particularly crazy sound improvement and so I have pretty much decided on the standard Dansk offerings or Porsche OEM Motor Sound mufflers (although I understand the OEM items are quite a bit louder than standard - no big deal :thumb:).

I shall replace the catalytic converter if required as well and of course the heatshields for the cat, mufflers, heat exchangers and the many sundries I expect to have to have cut off or drilled out. As I shall be doing the the whole system; what is a brief list of the main components I'll need to replace if doing a thorough job?

Generally, am I correct in assuming the heat exchangers are pretty solid and probably won't require replacement? At 1.5k per side I'd like to be forwarned of the likeliness of failure.

Excluding the possible heat exchanger drama I'm budgeting around 3k supplied and fitted for the whole project (likely to be done by Precision Porsche). Is this realistic or do I need to up my game?
 
For a start as your wanting to replace every not, bolt and bracket; whilst supping a coffee, why not order the parts yourself via the PET catalogue....... I found it quite an enjoyable experience. I also found OPC to be no more expensive at times and they'll give you at least a 10% discount if you ask, though I'd be scouring the likes of Europarts etc aswell. Why spend the dosh at an Indy to order and mark up prices and because they're 'Specialists', their labour charges. It's an exhaust system and needs no special knowledge. There are big savings to be had on labour if you know of a decent back street spanner man.

The heat exchangers have a protective outer skin, my right hand one has a small hole in it, and my 993 goes in this Monday to have it welded as well as other exhaust work. The actual heat exchanger is beneath this outer skin and should be in fine fettle. ...... This is what a good spanner man will point out, repair, rather than replace replace replace.

I had my silencers altered to RSR spec by Carnewell. ....... To my ears its a perfect balance of deeper growl, extra noise but without being either too loud or boomy.

My exhaust system has covered over 140k miles and is generally in very good shape, my CAT is fine so Id expect your CAT to be fine also, though whilst your stripping the rest you might think of having it converted to 200 cell for a bit more ooomph and noise if that rocks your boat.

It won't be your exhaust system that's knackered, it will be the likes of heatshields, clamps etc that make it look knackered, also check/replace heater pipes from the heat exchanger and unless they've been replaced already, think of installing new bumper stays, which if looking ropey may as well be replaced at the same time as the exhaust is off.

I've just bought new bumper stays, silencer straps, associated nuts and bolts and the heat shield for the CAT, and that was just shy of £500.00. I expect there to be more cost as the system is being taken apart. So expect every bolt and clamp to be rusted solid, and if you head OEM, expect it to cost a small fortune........ but nowhere near £3K inc labour. :what:

Whilst your in there, replace the oxygen sensor to the CAT . It should really be replaced every 30K miles or so...... go OE, but not Porsche and save around 60% for exactly the same item.

Lastly I'm a great believer in sticking with OEM parts for the actual exhaust parts, you know they will fit.
 
Wozy, thanks so much for taking the time for your fabulous reply. Very much appreciated!

As you suggest shopping via the PET catalogue would indeed be fun and is probably a route I shall take i.e. doing the sourcing of parts myself.

Great news regarding the heat exchangers so fingers crossed on that. Sound advice on staying OEM.

ATB
 
Worth speaking to Gert at Carnewell, I think he has some old 993 stock.

Dan
 
Woa - you are in for some serious expenditure.

I did all that stuff DIY a couple of years ago and there sure are a lot of bits that need replacing and none of them are cheap. Adding on the cost of paying a professional to do it may even push you over budget.

Some say that Dansk exhausts are not up to much in terms of quality so you may want to consider OE.

The slightly frustrating part for you will be none of the improvements proposed are visible or very aural although it will give you that nice fuzzy warm feeling knowing everything is solid and clean and shiny under there.

If the cat is original at least go for the 200 cell mod by Powerflow which is good value at about £400 or so. Better flow and a bit of a bark.

For a visible improvement you'll be surprised and delighted at how well the standard exhaust tips can be polished up. The standard finish is very flat but an hour's work on a polishing wheel brought up a lovely mirror finish that has lasted well.
 
If you go with a sport Kat then go with a decent quality like the HJS from Carnewal. :thumb:
 
kerb scraper said:
For a visible improvement you'll be surprised and delighted at how well the standard exhaust tips can be polished up. The standard finish is very flat but an hour's work on a polishing wheel brought up a lovely mirror finish that has lasted well.

I had mine done in 2010 and this is how they came up :thumb:

ATB :)
 

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Ta again gents. I have replaced the old tips with Dansk 8mm rolled tailpipes which I love. The old tips were in a bad way and there was no saving them.

In the end I decided against original tips (too small) or big ovals (more important things to spend the dough on - car needed some major TLC when initially purchased). I ended up grabbing some new Dansk tips for 50 quid from a chap on eBay who had just sold his 993. You can't argue with that!
 
MattyR said:
Ta again gents. I have replaced the old tips with Dansk 8mm rolled tailpipes which I love. The old tips were in a bad way and there was no saving them.

In the end I decided against original tips (too small) or big ovals (more important things to spend the dough on - car needed some major TLC when initially purchased). I ended up grabbing some new Dansk tips for 50 quid from a chap on eBay who had just sold his 993. You can't argue with that!

I've got the same, bloody brilliant at the price and look great 👍
 
Yes I think you're on the right lines, all those bolts and heat shields etc soon add up for sure, I think I have everything I need now for when it all goes back together including new Porsche RSR boxes from Gert (mine were past recovery) so can't wait till I'm at that stage.

The bolts that connect Cat to header will be shot, in fact I had a few missing bolt heads, the rest I just stripped off, will need to take to my old mans for some serious heat to remove the remaining bolt from the cat.

Headers came off the engine ok will no stripped nuts/studs, they seem in great shape albeit very dirty so they will get a good cleanup.

Hoping it should last another 20 years when done :)

Trev
 
Whilst they're off you might consider getting them polished? I'm off to Oldham today to take my new to me exhaust to get polished. For the 2 side cans and the cross over pipe it's £90. I managed to get the side cans to a very reasonable state but the tight areas of the pipework I can't do. By the time I bought all the bits and pieces along with the time it takes, I've thrown up the white flag. Cheaper for them to do it. Apparently do it for Aston Martin
Something to consider whilst they're off?
 
Are you talking about polishing the mufflers here?, if so for what purpose?.

I've had a go at my tailpipes with Autosol, I'm not completely happy yet so could do with them doing on a wheel.

Trev
 
I was referring to the headers. I imagine they're purple and crusty. You could get the headers cleaned up with shotblasting to get them back to a lovely state.nthe exhaust if it's stainless will polish up a treat
 

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