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Old 14-03-2019, 05:38 PM   #331
gadget555
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I've been out for a 16 mile shakedown test (to book an mot), and everything seems fine, no leaks, nothing has worked loose & fallen off, 1 problem has now appeared, it's now a lot noisier than it was with the mild steel one on to the extent that the drone that it now creates is very sore on my sensitive ears. I have some ear plugs that I put in my right ear when I have the window open while having a smoke (stops the buffeting noise) Has anyone any recommendations of a intercom system, like they have in rally cars? I would be looking at the can type ear defenders something to try and cut out the drone.
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Old 14-03-2019, 06:20 PM   #332
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Build one for an Autocom bike intercomm and 2 peltor ear defenders.

Thats what I did.


Last edited by Ken555; 15-03-2019 at 11:32 AM.
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Old 14-03-2019, 07:31 PM   #333
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I'm about to go all stainless steel Keith. Is there anything you can recommend or steer me away from? My current exhaust is 2 1/4 I think.
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Old 15-03-2019, 09:29 AM   #334
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Not really no, I bought the everything from ebay bar the v-bands which I got from Darkside developments, the only thing I can say is if your building it your self? try & make sure you have a small straight piece coming off the manifold blank as this helps when trying to get the bend to the right angle, take your time and the finish will look professional. I asked Dan for as many photos of his manifold as he could get me & tried to copy it the best I could, try and get the slip joints to be straight as possible going into the collectors because any slight angle and it's can be a biatch getting them together and apart! I thought I would be able to pick tig welding back up like riding a bike but I was wrong so bought some stainless mig wire and tacked the piece's together and got a professional welder to tig it up for me, make sure that the section that your going to get welded up is braced or has the the collector slipped on the joint as the stainless will shrink & expand which will pull it out of line, also when getting the primary's welded to the manifold blank if you've got a spare head take it with you and bolt the blank to the head before welding the primary's on as mine the blank warped slightly! Size wise it's made to the same size as what Dan's is 38mm 1 1/2" primary's going into the collectors then 45mm 1 3/4" secondary's then into a 2" (I think Dan's is 2 1/4") pipe that goes to the silencers and I think my tail pipe is 3" I think my total cost excluding the silencers was £400 including £100 for the welding, seems expensive but when you way up the cost of a full Simpson system being about £1800 + vat then it's quite cheep!
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Old 15-03-2019, 09:49 AM   #335
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Unfortunately stainless systems do tend to be louder than I mild system, your 3” tailpipe won’t help, think mine is 2.25” which matches my system.
Fortunately for me, my tailpipe points down as it’s tucked away under the boot floor so it didn’t need to look pretty hanging out the back, this helps reduce noise.
I found the best way to get rid of exhaust noise was to fit a set of Jenvey’s, this works really well at drowning out all noises!


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Old 15-03-2019, 10:41 AM   #336
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"I found the best way to get rid of exhaust noise was to fit a set of Jenvey’s, this works really well at drowning out all noises!"
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Old 15-03-2019, 12:41 PM   #337
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It appears we are worlds apart in the design and cost involved in exhaust making. I am about to swap my entire exhaust too so have been collecting parts in order to do this.

Mine is going to be considerably cheaper.

I am going to swap the 4 bolt manifold for a 6 bolt. These are more free flowing.

Use a ZR 160 front pipe.

Both these I have been given off Kyle.

Then I bought ages ago a "Japanese import classic Mini exhaust". It's twin box 50mm bore system for the classic Mini. This I won on eBay for £10.

I have arranged for my garage to fit these this week.

I did a in car noise test. Under hard acceleration it's 93db or steady 70mph was 83db. This is a cherry bomb setup.

I will test again after the new system is fitted.
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Old 15-03-2019, 01:08 PM   #338
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Quote:
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It appears we are worlds apart in the design and cost involved in


........everything!


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Old 16-03-2019, 10:14 AM   #339
gadget555
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Well that's another 12 month ticket on the mini, passed with no adversaries!
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Old 16-03-2019, 06:26 PM   #340
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Winner!


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