Need a new exhaust system - what do I need to know?

If I haven't admitted it on this site before, let me start by saying that when it comes to cars, I'm pretty ignorant. Not a gearhead growin gup, so I'm working hard to educate myself. Reading through the "Essential 996" page by page is helping, but still a long way to go. I need a new exhaust system. My mufflers had bad cracks in them and I have one undersized Cat. We patched it up with some ceramic exhaust "paste" but it's not a long term solution. A few questions: - I have the sport exhaust system on my car. What, physically, does this consist of? If I put on a new exhaust system, will this feature be lost? Should I care? - What are the biggest differentials in aftermarket systems? Is sound the primary factor here? I know there are some performance claims, but not sure how much of that is bogus. - Other than the risk of annoying the driver, are there any downsides/risks to going with an aftermarket race exhaust system? - Recommendations on brands/products? Thanks!

I personally would just buy a used system and install it. You can find them on craigslist, etc. I would do the fister mod before putting it on if you like it more sporty. I believe the sport system is essentially a fister mod on demand with the vacuum assist to connect the inlet/outlet.

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My entire system is pretty corroded, so it really does need to be replaced. I know the fister mod is popular, but I'm not sure I'd want to try to do any modifications to a system that's in such bad shape. Used is definitely a preferred option... Here's what I'm dealing with right now:

Andrew: your "answer" depends on how far back you want to go. Are your stock headers in good shape? New OEM cats will run approx $2,500.00 each, from Porsche. After that you need mufflers, (i.e., cans) and pipes. If this is a street ride, I would suggest you stay away from any "race" exhaust system. The noise level alone would be a deal killer, even if a used ( i.e., cheap) one could be found. Another thing to consider is where you are located. Changing exhaust (cats) if they are not stamped carb compliant, can result in an inability to pass local state inspection. You might be okay, as one of the cats is bad and this would be a replacement, but I would check b4 spending $$$$$. If you can replace cats and exhaust, a solid used system is cheaper, make sure the used cats are in good shape, along with the rest of the system, (ie., cans and exhaust piping), otherwise its a waste of effort and dollars. Good luck hunting. If you go aftermarket, there are a number of reputable mfg. Fabspeed, Cargraphic, Brombacher, etc., As a suggestion you will want German made cats (usually hi flow-such as 200 cell= less back pressure, (might give up some low end torque?) Be careful of Chinese made cats! Yes, they are cheaper, but you get what you don't pay for (less quality). Regardless of what you do, which way you go, I highly recommend the Fister D modification. It is a bargain ($$) and the sound is amazing, no drone at any speed, great work by Darin's shop for quality modification and simply enjoyable exhaust note......so much so, that you want to keep you foot in it all the time! GL Hope this helps ( I am no expert either, there are a few in here who know way more)

I said to buy used on craigslist or on the classifieds. They can be had cheap.

Sent a pm about my catalytic converter for sale. Like I said, feel free to make an offer. I just need them gone, their oem in working order. I suggest an aftermarket system, I have muffler bypass pips, it's loud...now I have cat bypass along with those...sounds awesome! ! ! But, it's very loud and many people probably wouldn't appreciate it. With that said a full cat back might be the way to go, mufflers and all. For good tone, a bit more flow, and not crazy loud in the cabin

There are a plethora of options available to you . I have the Fister D Titanium cans, and Speed Venture X-pipe with the 200 cell high flow cats. It is very exciting so get out there and get educated before you buy

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I also have the sport exhaust option. It is basically a partial bypass, similar to the Fister mod, but with an on/off button (vacuum controlled valve). If you are like me and always drive with the exhaust in sport mode then you will probably like the Fister mod as well. I went one step further when one of my cats went - cat delete with custom center muffler instead (with ECU chip). Slightly louder again and very addictive sound under hard acceleration.

Hey Andrew...glad to see you're back on the road. Grats on the new family addition as well. You had one heck of a great week! As for exhaust here's my $0.02: Headers : don't fuss with them unless they need replacement. There are many claims from aftermarket header sellers about performance gains, my synthesis of them all is that headers "may" result in higher HP at high RPMs but loss of low- and mid-range power and torque. For a daily driver, that's exactly what you DON'T want to lose. Cats : lots of choices here. Auto Atlanta sells a 50-state replacement (but not OEM) cat for about $775 per side. Genuine Porsche replacement cats cost about $1775 per side. Most aftermarket options are for 200-cell "race cats" which reportedly do a fine job and won't result in tailpipe emissions testing problems but are technically not legal for road use. Aftermarket options include both OEM-style as well as "x-pipe" (different configuration, reportedly for HP/torque gains). These aftermarket options are in the $2K +/- 10% range. For stock configuration, AWE is whose I'd use--I have their mufflers. For x-pipe configuration I would personally opt for FVD's, which are made by M&M in Germany over anyone else's based on forum posts; there are many others out there selling x-pipe systems but they get mixed reviews for performance, quality, and/or customer service. Personally I won't purchase used cats unless they come with a 100% replacement guarantee from the seller that they will successfully pass a state emissions test. Mufflers : if you want to retain full functionality of your factory sports exhaust, your options appear to be Genuine Porsche ($$$$) or Cargraphic, who offer a muffler set with switchable bypass that connects directly to the factory controls for about 1750 Euros (figure $2K+). If you are okay with losing the switching function of your factory system you have a myriad of options. Buying a pair of used stock mufflers and then having FisterD modify them is going to yield a sound closest to your sports exhaust system at a reasonable price ($300 plus 2-way shipping to California plus whatever you pay for the used mufflers). Brand new aftermarket mufflers are in the $2K+ range and you need to beware of droning. As noted before, I opted for AWE and love them but for maximum fun/money I'd go the FisterD route were I to do it again. Enjoy! Rich

Brand new factory cats can be had for $2700 for both from sonnen Porsche parts.

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Good to know, thanks. I've never found a good reason to shut off the sport exhaust, so I'm sure the Fister mod would be to my liking as well!

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Rich, really helpful post, thanks. It's definitely been an exciting week! Driving the car all week has really just been icing on the cake. I've heard a lot of good things about the AWE products and have talked to two mechanics locally who have both recommended them. Other than the fact that I have mis-matched cats, I don't think there's any real driver for replacing them; I had them inspected and the work fine. Same with the headers. So that leaves the mufflers. I don't particularly need the switching function for the factory sport exhaust, so an aftermarket solution would be a viable option. Whether new or used, I'm hoping to get some input on specific models to avoid a set that I'll need to remove in a year due to the droning. I was tempted to jump on a set of very lightly used FabSpeed mufflers being sold locally at a great price, but I've heard they're a bit too much on the ears for DD use. How do you find your AWEs?

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William, thanks for the PM. After just replacing the engine and a bevy of other components, I'm probably 2-3 months out before I get this exhaust work done, so not quite ready to make any purchases. Do you use yours as a daily driver? I don't think the noise would bother me, but it's hard to tell until you have to put up with it!

I have a set of used Fabspeed mufflers for a 996 if anyone is interested. I keep meaning to take some photos and post them on the classified. I'll do that later this week but PM me with offers Thanks John

In a thread where I already admit my ignorance, I'm going to ask an even 'stupider' question: How do I know if my PSE is even engaged? Seriously, I spent my entire drive home from work today (~75min) switching the PSE butting in about every condition possible (all revs, accelerating, steady, low speeds, 80+ mph), and I couldn't hear a difference under any conditions. This includes on back roads with my windows down and little other background traffic noise. I assume this means the PSE isn't toggling, but I can't tell if it's stuck on ON or OFF. I'll go hang my head in shame now... ;-)

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Andrew, You can look under and see if you are manually able to push in the actuator valve. If it's stuck, you probably have frozen pivot point. If you're able to push it in, next hold it in and disconnect vacuum hose and put your finger over the diaphragm valve to see if it holds. If the actuator comes back out while your finger is over the diaphragm then you have a bad diaphragm. If it passes both these tests, test your solenoid with a vacuum gauge to see if that's the culprit. The loud mode is the default without any vacuum hooked up to it so most likely if your system were to fail, it would be stuck in loud mode. Guessing by the cracks you have, it would be hard to tell if you're in loud mode since it will always be on the noisy side.

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It'll have to wait until Friday, but I'll check that out as soon as I can. See I find the current sound a bit subdued. If if fails to open, then maybe I'm better suited for something louder!