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C11BRA
Imola


Joined: 30 Mar 2015
Posts: 751
Location: North London. Herts.


PostPosted: Mon Jan 27, 2020 9:39 pm    Post subject: Reply with quote

Tight radius pipes arrived today. Will decide on final location before Fridays welding session.


_________________
2006 997.1. Project GT3C. C stands for ???
2018 Audi A4 Avant Black Edition.
Ex 996 C2 Man.
Ex Ram Cobra V8.
Ex Series 1 RS Turbo.

 
  
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TopGear Exhausts
Approved Trader


Joined: 22 Feb 2018
Posts: 90
Location: Bridport, UK


PostPosted: Wed Jan 29, 2020 5:26 pm    Post subject: Reply with quote

What a fine thread! Loving the obligatory "Porsche mugs" thumbsup
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C11BRA
Imola


Joined: 30 Mar 2015
Posts: 751
Location: North London. Herts.


PostPosted: Thu Jan 30, 2020 12:52 am    Post subject: Reply with quote

Thank you TOP GEAR exhausts.

Made myself a quick jig to ensure the tailpipes align after modifications.



Every rusty mild steel bolt was rotten & siezed. It blows my mind why they were fitted.



Every new bolt, nut, clamp and washer will be stainless steel or titanium.


_________________
2006 997.1. Project GT3C. C stands for ???
2018 Audi A4 Avant Black Edition.
Ex 996 C2 Man.
Ex Ram Cobra V8.
Ex Series 1 RS Turbo.

 
  
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Phil 997
Le Mans
Le Mans


Joined: 05 Dec 2015
Posts: 15744
Location: Bournemouth,Dorset

2009 Porsche 997 Carrera 4S

PostPosted: Thu Jan 30, 2020 3:29 pm    Post subject: Reply with quote

WOW your being thorough Thumb Thumb taking the time even to etch GT3C on the exhaust jig Grin Thumb
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Others Enjoy The Moment Today.
 
  
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C11BRA
Imola


Joined: 30 Mar 2015
Posts: 751
Location: North London. Herts.


PostPosted: Sun Feb 02, 2020 11:36 am    Post subject: Reply with quote

Sorry Mr Porsche.

I’ve have had to redesign your exhaust mount. (Simply because I can refit it as I had to cut the old parts out due to clearance issues with the sports manifold fitted).

As I’ve already said, I refuse to refit any mild steel nuts & bolts. And the front silencer mounts originally had a steel tube with the wire mesh bushes at the top and bottom. Bushes great. Rusty tube, not great. And I couldn’t refit the long bolt once the tube is in place.

So. I made these. Stainless tube for the shorter rear (with titanium bolt) & a solid stainless long bar for the front. I tapped M8 threads in each end to accept a stainless short bolt (that fits under the chassis rail at the top, and above the manifold on the bottom). The M6 bolt fitted half way is to stop the rod spinning when I come to remove the bolts in the future. The bolt is tight in the rod, but allows the wire mesh movement so it floats in the exhaust mount. Let’s see how it goes.



Floating anti spinning bolt. (Technical description)



M8 thread visible. Floating bar made it easier to get bolt in.


_________________
2006 997.1. Project GT3C. C stands for ???
2018 Audi A4 Avant Black Edition.
Ex 996 C2 Man.
Ex Ram Cobra V8.
Ex Series 1 RS Turbo.

 
  
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C11BRA
Imola


Joined: 30 Mar 2015
Posts: 751
Location: North London. Herts.


PostPosted: Mon Feb 03, 2020 10:32 pm    Post subject: Reply with quote

After an epic amount of welding equipment failures, I have finally finished the bypass valve fit to the drivers side and re-attached the centre exit tail pipe.

Feels very strange, welding at home. But great fun.



Hopefully fitted for the last time.


_________________
2006 997.1. Project GT3C. C stands for ???
2018 Audi A4 Avant Black Edition.
Ex 996 C2 Man.
Ex Ram Cobra V8.
Ex Series 1 RS Turbo.

 
  
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C11BRA
Imola


Joined: 30 Mar 2015
Posts: 751
Location: North London. Herts.


PostPosted: Fri Feb 07, 2020 12:56 pm    Post subject: Reply with quote

Final push (hopefully) this afternoon.

My knees are killing me.


_________________
2006 997.1. Project GT3C. C stands for ???
2018 Audi A4 Avant Black Edition.
Ex 996 C2 Man.
Ex Ram Cobra V8.
Ex Series 1 RS Turbo.

 
  
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C4Silver
Spa-Francorchamps


Joined: 14 Aug 2019
Posts: 346
Location: Yorkshire


PostPosted: Fri Feb 07, 2020 1:10 pm    Post subject: Reply with quote

I absolutely have NO Idea what that mesh thing is or what it does Dont know

Your attention to detail however is First Rate, as is your technical ability, Welding at home however.... On what looks like an Old Army blanket should keep you on your toes.
worship

As for the Picture of all things SHINY Smile You should maybe look at bagging these up and selling them as kits, OR..... Better still...... IN YOUR SPARE TIME you could fit them for us Question

Top work, and looking forward to seeing your hard work at a show or meet at some point this year,
bye
_________________
997.1 Carrera 4S, GT Silver, Aero Body Kit,
 
  
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C11BRA
Imola


Joined: 30 Mar 2015
Posts: 751
Location: North London. Herts.


PostPosted: Sat Feb 08, 2020 12:24 am    Post subject: Reply with quote

C4Silver wrote:
I absolutely have NO Idea what that mesh thing is or what it does Dont know

Your attention to detail however is First Rate, as is your technical ability, Welding at home however.... On what looks like an Old Army blanket should keep you on your toes.
worship

As for the Picture of all things SHINY Smile You should maybe look at bagging these up and selling them as kits, OR..... Better still...... IN YOUR SPARE TIME you could fit them for us Question

Top work, and looking forward to seeing your hard work at a show or meet at some point this year,
bye


Thank you. I do get a bit carried away huh?

All done. And road tested. Sounds just how I hoped. Lovely tone in quiet mode (hopefully good enough for Spa DB level test. And Wow!!!! Spectacular with both valves open. Less aggressive than the de-cat & Designtek sports silencers that was previously fitted. But still great for when the misses is not in the car (aka fun-sponge!).



NS valve plumbed in with stainless pipe.



Valves fit nicely under heat shields.



X pipe looks pretty cool between the tailpipes.


_________________
2006 997.1. Project GT3C. C stands for ???
2018 Audi A4 Avant Black Edition.
Ex 996 C2 Man.
Ex Ram Cobra V8.
Ex Series 1 RS Turbo.

 
  
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C11BRA
Imola


Joined: 30 Mar 2015
Posts: 751
Location: North London. Herts.


PostPosted: Sat Feb 08, 2020 2:39 am    Post subject: Reply with quote

This might give you an idea of how tricky it was converting the the centre exit tailpipes to the stock (gundo modded) silencers.




_________________
2006 997.1. Project GT3C. C stands for ???
2018 Audi A4 Avant Black Edition.
Ex 996 C2 Man.
Ex Ram Cobra V8.
Ex Series 1 RS Turbo.

 
  
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NLW73
Albert Park


Joined: 27 May 2014
Posts: 1605
Location: Yateley


PostPosted: Sat Feb 08, 2020 7:41 am    Post subject: Reply with quote

That is great work and well done

The gt3 centre pipe is an awesome look

How does it drive or not had chance? It should be torquier at the lower end and still make the nice shrill and roar up to the top end
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997 C2s Schwarz
 
  
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C11BRA
Imola


Joined: 30 Mar 2015
Posts: 751
Location: North London. Herts.


PostPosted: Sat Feb 08, 2020 10:31 am    Post subject: Reply with quote

First road test was at 8pm last night so with mechanical empathy, I was just running everything up to temperature, resetting steering angle sensors etc. Stopping at every service station for a quick check etc. Always a bit of burning off of oils, joint sealant etc. It can be quite smoky but wasn’t too bad. Got followed by the Police for a mile. I thought I was going to get a pull but didn’t.

So. No real performance runs yet. What I did notice is a sweet spot at about 2500 rpm where the sound just peaks with a buzz. Just lovely.

On my second service station stop I connected my temporary vacuum system to operated the 2 gundo valves for the first time. Both worked perfectly. And nice that they are just visible from under the bumper. Oh wow. Even at idle, it was transformed. I set off down the A1 towards home. Under the M25 flyover, I couldn’t resist an idiot blip. Really really nice sound. Not as viscous as the system I’ve just removed, but really deep and just perfect for how I wanted it to be.

All in all, I couldn’t be happier.

The quiet mode will be a blessing on our long Euro trips we hope to enjoy in the coming years and hopefully will pass the track day DB tests with ease. (Although the X pipe possibly makes it louder than stock. I’ve never driven a stock 996 or 997).

The idiot mode will be great for Ace Cafe meets & tunnel hunting with my 13 year old lad.

All I need to do now is figure out how to activate the valves via the GT3 (spoiler button delete) switch pack I installed recently. I already use the suspension & TC off buttons but I have pre-wired the redundant sport button for this very purpose. (My car is non sport). I truly hope I can work out how to use the spare sport signal to operate a relay & then the solenoid to make the exhaust mode operation appear to be factory fitted. Things like that give me a buzz.
_________________
2006 997.1. Project GT3C. C stands for ???
2018 Audi A4 Avant Black Edition.
Ex 996 C2 Man.
Ex Ram Cobra V8.
Ex Series 1 RS Turbo.

 
  
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Alfaian
Imola


Joined: 12 Mar 2014
Posts: 833
Location: S.wales


PostPosted: Sat Feb 08, 2020 12:40 pm    Post subject: Reply with quote

Superb work mate Thumb

Any chance of a video to hear it please Grin
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Arctic silver C2S
 
  
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C11BRA
Imola


Joined: 30 Mar 2015
Posts: 751
Location: North London. Herts.


PostPosted: Sun Feb 09, 2020 4:14 pm    Post subject: Reply with quote

Alfaian wrote:
Superb work mate Thumb

Any chance of a video to hear it please Grin


Your wish is my command.

Not ideal road testing weather today. But no chance of getting hit by a falling tree in a tunnel. That’s the only reason I went through it. Honestly.

https://youtu.be/eNebwi83xqA



I will try and do some more video when I do my static DB trials.

But all in all, I couldn’t be happier. And the performance feels unaffected by the reintroduction of the 200 cel cats. Bonus.

Just need to wire in the solenoid valve now. And wait for nicer weather.
_________________
2006 997.1. Project GT3C. C stands for ???
2018 Audi A4 Avant Black Edition.
Ex 996 C2 Man.
Ex Ram Cobra V8.
Ex Series 1 RS Turbo.

 
  
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Alfaian
Imola


Joined: 12 Mar 2014
Posts: 833
Location: S.wales


PostPosted: Sun Feb 09, 2020 4:36 pm    Post subject: Reply with quote

Surprised sounds fantastic Grin
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Arctic silver C2S
 
  
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Phil 997
Le Mans
Le Mans


Joined: 05 Dec 2015
Posts: 15744
Location: Bournemouth,Dorset

2009 Porsche 997 Carrera 4S

PostPosted: Sun Feb 09, 2020 5:00 pm    Post subject: Reply with quote

Sounds great in the vid , and a really good build thread Thumb Thumb
_________________
911 Owners,Some Invest In The Future,
Others Enjoy The Moment Today.
 
  
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C11BRA
Imola


Joined: 30 Mar 2015
Posts: 751
Location: North London. Herts.


PostPosted: Mon Feb 10, 2020 11:03 pm    Post subject: Reply with quote

Had to remove quite a fair bit of interior to find a way through from the cabin to engine bay. Thought it best to follow the engine loom from the DME.

Found the large bulkhead grommet was not fully pushed into place. This allowed some dust into the cabin but too high to allow water in. Nothing else suspicious so I suspect it may have been like this since the factory. Hoping the cabin will be even quieter than just the silencer upgrade.



Latching relay due this week then I’ll wire in the valves.
_________________
2006 997.1. Project GT3C. C stands for ???
2018 Audi A4 Avant Black Edition.
Ex 996 C2 Man.
Ex Ram Cobra V8.
Ex Series 1 RS Turbo.

 
  
View user's profile Send private message
   
C11BRA
Imola


Joined: 30 Mar 2015
Posts: 751
Location: North London. Herts.


PostPosted: Tue Feb 11, 2020 10:34 pm    Post subject: Reply with quote

Interior back in. Grommet pushed home (very satisfying), wiring run to centre console & vacuum pipes/valve fully fitted.




Special relay due tomorrow so all I can do is prepare the wiring loom tonight.



Big day tomorrow. Hopefully.
_________________
2006 997.1. Project GT3C. C stands for ???
2018 Audi A4 Avant Black Edition.
Ex 996 C2 Man.
Ex Ram Cobra V8.
Ex Series 1 RS Turbo.

 
  
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systech1
Monza


Joined: 10 Jul 2016
Posts: 150
Location: Adelaide, South Australia


PostPosted: Wed Feb 12, 2020 5:30 am    Post subject: Reply with quote

C11BRA wrote:
First road test was at 8pm last night so with mechanical empathy, I was just running everything up to temperature, resetting steering angle sensors etc. Stopping at every service station for a quick check etc. Always a bit of burning off of oils, joint sealant etc. It can be quite smoky but wasn’t too bad. Got followed by the Police for a mile. I thought I was going to get a pull but didn’t.

So. No real performance runs yet. What I did notice is a sweet spot at about 2500 rpm where the sound just peaks with a buzz. Just lovely.

On my second service station stop I connected my temporary vacuum system to operated the 2 gundo valves for the first time. Both worked perfectly. And nice that they are just visible from under the bumper. Oh wow. Even at idle, it was transformed. I set off down the A1 towards home. Under the M25 flyover, I couldn’t resist an idiot blip. Really really nice sound. Not as viscous as the system I’ve just removed, but really deep and just perfect for how I wanted it to be.

All in all, I couldn’t be happier.

The quiet mode will be a blessing on our long Euro trips we hope to enjoy in the coming years and hopefully will pass the track day DB tests with ease. (Although the X pipe possibly makes it louder than stock. I’ve never driven a stock 996 or 997).

The idiot mode will be great for Ace Cafe meets & tunnel hunting with my 13 year old lad.

All I need to do now is figure out how to activate the valves via the GT3 (spoiler button delete) switch pack I installed recently. I already use the suspension & TC off buttons but I have pre-wired the redundant sport button for this very purpose. (My car is non sport). I truly hope I can work out how to use the spare sport signal to operate a relay & then the solenoid to make the exhaust mode operation appear to be factory fitted. Things like that give me a buzz.


DucatirRob, myself and others have used the OEM PSE switch panel via a latching relay (rather than via the ECU) to control the vacuum solenoid as described in detail here....http://911uk.com/viewtopic.php?t=116327&highlight=systech1.

Works very well and remembers the last setting as a bonus
_________________
Long time Porsche fan. Previous cars include 911T 2.2, 911E 2.2, Carrera 3.0, 986 Boxster S. Current car is 997.2S Manual (with PSE, H&S Backbox bypass, Sports Chrono, SSK, DSC PASM controller, Carrera Sports wheels, Ducktail/Diffuser and splitter, Sport Design steering wheel etc.)
 
  
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stucart
Montreal


Joined: 24 Apr 2013
Posts: 566
Location: staffordshire 07 997 C4S


PostPosted: Wed Feb 12, 2020 9:09 am    Post subject: Reply with quote

Superb work, really impressed with attention to detail and workmanship. worship
_________________
Now - Jaguar F-Type 2014 3.0 S Quickshift ,White/ Red interior (theme here!) Loving it .
Previously - 997 C4S Tip-S, 2007, Silver/Red and Black Leather, PSE, Sports Chrono, Turbo wheels.
 
  
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