New Race Exhaust - LotusTalk

Mase · 11-04-2008, 09:49 AM

Hello all,

I haven’t posted here, however I’ve been lurking around for awhile, I’ve recently been doing some r&d with the lotus exige, making a liquid to air intercooler, as well as a header back race exhaust.

A client with a 07 exige S had his exhaust crack right after the factory cat. Stock header, stock cat, with a slip on exhaust. This happened while out on the race track. Looking further into it. We noted a few things wrong here. Obviously with any welded material, the weakest point is usually the weld itself. Many mfg’s pump out high volume of product. You often see thin walled material crack. The other problem we saw, the lack of flexability. It has the flange joint where the header meets the cat, however I don’t believe its giving it enough room to flex. The mounting of the canister is quite stiff.

We designed a complete header back exhaust. Using proper flex section, thick walled stainless 304. Being a track car, we opted for no cat (this exhaust is not street legal). We didn’t want to make anything raspy or too annoying, but we wanted to make something great throaty sound, that flows a bit better than stock. We wanted a dual output, I am looking into getting new rear grills specifically made, however, modifying the stock ones were extremely easy. We will possibly make a lower exit stock location as well as one with a cat for street legal requirements.

Supercharger cars can be sensitive to backpressure. The car made 230 whp moderately warm (did this while we were testing the new liquid to air intercooler) with only a reflash, the new intercooler, and this exhaust as the modifications. More testing between the stock exhaust/slip on back to back with this new exhaust will be done very soon.

Pics:

Video:

<object width="400" height="300"><param name="allowfullscreen" value="true" /><param name="allowscriptaccess" value="always" /><param name="movie" value="http://vimeo.com/moogaloop.swf?clip_id=2148195&server=vimeo.com &show_title=1&show_byline=1&show_portr ait=0&color=&fullscreen=1" /><embed src="http://vimeo.com/moogaloop.swf?clip_id=2148195&server=vimeo.com &show_title=1&show_byline=1&show_portr ait=0&color=&fullscreen=1" type="application/x-shockwave-flash" allowfullscreen="true" allowscriptaccess="always" width="400" height="300"></embed></object><br /><a href="http://vimeo.com/2148195">Untitled</a> from <a href="http://vimeo.com/user505353">Mase</a> on <a href="http://vimeo.com">Vimeo</a>.

Regards,
Mase

PatrickShim · 11-04-2008, 10:04 AM

Was this one-off, or are you going to take orders?

$$$?

I'd be interested. I have Stage-II right now, and have been dealing with weld cracks over and over....

Mase · 11-04-2008, 10:29 AM

Quote:

Originally Posted by PatrickShim

Was this one-off, or are you going to take orders?

$$$?

I'd be interested. I have Stage-II right now, and have been dealing with weld cracks over and over....

We can certainly take orders, Intro price will be $895 (to generate market share). After that it will be more. Much more affordable compared to even some slip ons.

PatrickShim · 11-04-2008, 10:33 AM

Any known P0420 code issues? That's pretty common with these types of setups.

Mase · 11-04-2008, 10:46 AM

Quote:

Originally Posted by PatrickShim

Any known P0420 code issues? That's pretty common with these types of setups.

we have a easy trick around that. Car has put 400 miles so far without a code.

shay2nak · 11-04-2008, 10:53 AM

how much does it weigh? What's the muffler diameter?

Monsi · 11-04-2008, 10:55 AM

would it be possible to make it fit an 08?(central exhaust exit) probably require a slightly different muffler
I assume when you say header back you mean you left the stock headers in place

Mase · 11-04-2008, 10:59 AM

Quote:

Originally Posted by shay2nak

how much does it weigh? What's the muffler diameter?

I will measure weight of the entire exhaust. the main section is 2.5" outlets are 2.25".

Mase · 11-04-2008, 11:01 AM

Quote:

Originally Posted by Monsi

would it be possible to make it fit an 08?(central exhaust exit) probably require a slightly different muffler
I assume when you say header back you mean you left the stock headers in place

It will require a different canister for central exhaust exit. That will be in the works shortly. I need to research the differences between all the years.

And yes, stock headers still in place.

skibum · 11-04-2008, 11:18 AM

Is this the same Mase that does a lot of turbo S2K AEM tuning?

probax · 11-04-2008, 11:59 AM

The sound is insane but would be much too loud for me. Do you still have neighbours who might complain or are they already deaf

I've driven a Quicksilver for some thousend miles. Sound was great but what's really annoying at least on longer trips is the drone inside. Do you have the same problems with this one?

Mase · 11-04-2008, 12:01 PM

Quote:

Originally Posted by skibum

Is this the same Mase that does a lot of turbo S2K AEM tuning?

heh, yes thats me!

I dont know why my website is down right now. should be back up in a few...

Mase · 11-04-2008, 12:03 PM

Quote:

Originally Posted by probax

The sound is insane but would be much too loud for me. Do you still have neighbours who might complain or are they already deaf

I've driven a Quicksilver for some thousend miles. Sound was great but what's really annoying at least on longer trips is the drone inside. Do you have the same problems with this one?

This exhaust was not designed to be very quiet. I am going to offer a version with a cat and/or resonator for the people who want something a bit quieter.

It does not really drone too much, you can still talk normally even while cruising, and on track, even at WOT, conversation is still quite possible. maybe ill get some in car video...

plastique999 · 11-04-2008, 12:51 PM

Exhaust sounds amazing!!!!...sounds like my Eisenmann Race exhaust on my M6.

Is the internal diameter designed for S/C'd cars?

Mase · 11-04-2008, 12:56 PM

Quote:

Originally Posted by plastique999

Exhaust sounds amazing!!!!...sounds like my Eisenmann Race exhaust on my M6.

Is the internal diameter designed for S/C'd cars?

Yess I love the way it sounds. we spent some time configuring the sound

diameter before canister is 2.5". for the amount of exhaust flow the supercharged exige is flowing, 2.5" has been found to be ideal. If it was moving a lot more air. a larger exhaust would benefit. Even for an NA motor, it would probably do well, however, I have not tested it yet. i dont know the diameter of the stock exhausts on the non supercharged models. 60mm would probably work well with that.

shay2nak · 11-04-2008, 02:19 PM

Quote:

Originally Posted by Mase

I will measure weight of the entire exhaust. the main section is 2.5" outlets are 2.25".

thanks, how about the diameter of the can, 5 inches?

the tips are 3"?

FLuXeXigeS · 11-04-2008, 02:29 PM

any chance you will offer a single tip ???

more pics???

hp gains???

weight reduction or increase???

TiGumz · 11-05-2008, 09:35 PM

Quote:

Originally Posted by Mase

heh, yes thats me!

I dont know why my website is down right now. should be back up in a few...

Website must be still down, at least for my browser.....

Sh4rkattk · 11-05-2008, 10:17 PM

More pics of the muffler please.

edaddy · 11-06-2008, 09:35 AM

Quote:

Originally Posted by Mase

we have a easy trick around that. Car has put 400 miles so far without a code.

Will the trick work on other systems? If so, you may want to market that seperately....I'm interested!

11-04-2008, 09:49 AM	#1 (permalink)
Mase Registered User Join Date: Aug 2006 Posts: 32	New Race Exhaust Hello all, I haven’t posted here, however I’ve been lurking around for awhile, I’ve recently been doing some r&d with the lotus exige, making a liquid to air intercooler, as well as a header back race exhaust. A client with a 07 exige S had his exhaust crack right after the factory cat. Stock header, stock cat, with a slip on exhaust. This happened while out on the race track. Looking further into it. We noted a few things wrong here. Obviously with any welded material, the weakest point is usually the weld itself. Many mfg’s pump out high volume of product. You often see thin walled material crack. The other problem we saw, the lack of flexability. It has the flange joint where the header meets the cat, however I don’t believe its giving it enough room to flex. The mounting of the canister is quite stiff. We designed a complete header back exhaust. Using proper flex section, thick walled stainless 304. Being a track car, we opted for no cat (this exhaust is not street legal). We didn’t want to make anything raspy or too annoying, but we wanted to make something great throaty sound, that flows a bit better than stock. We wanted a dual output, I am looking into getting new rear grills specifically made, however, modifying the stock ones were extremely easy. We will possibly make a lower exit stock location as well as one with a cat for street legal requirements. Supercharger cars can be sensitive to backpressure. The car made 230 whp moderately warm (did this while we were testing the new liquid to air intercooler) with only a reflash, the new intercooler, and this exhaust as the modifications. More testing between the stock exhaust/slip on back to back with this new exhaust will be done very soon. Pics: Video: <object width="400" height="300"><param name="allowfullscreen" value="true" /><param name="allowscriptaccess" value="always" /><param name="movie" value="http://vimeo.com/moogaloop.swf?clip_id=2148195&server=vimeo.com &show_title=1&show_byline=1&show_portr ait=0&color=&fullscreen=1" /><embed src="http://vimeo.com/moogaloop.swf?clip_id=2148195&server=vimeo.com &show_title=1&show_byline=1&show_portr ait=0&color=&fullscreen=1" type="application/x-shockwave-flash" allowfullscreen="true" allowscriptaccess="always" width="400" height="300"></embed></object><br /><a href="http://vimeo.com/2148195">Untitled</a> from <a href="http://vimeo.com/user505353">Mase</a> on <a href="http://vimeo.com">Vimeo</a>. Regards, Mase __________________ http://www.MaseEngineering.com Website is up.

11-04-2008, 10:04 AM	#2 (permalink)
PatrickShim How you doin'? Join Date: Jul 2005 Location: Southern California Posts: 1,206	Was this one-off, or are you going to take orders? $$$? I'd be interested. I have Stage-II right now, and have been dealing with weld cracks over and over.... __________________ '06 Lotus Elise (Laser Blue/Black/Sport-Pack/Touring-Pack/Hardtop/TRD airbox/Stage-II Exhaust) - VIDEO

11-04-2008, 10:33 AM	#4 (permalink)
PatrickShim How you doin'? Join Date: Jul 2005 Location: Southern California Posts: 1,206	Any known P0420 code issues? That's pretty common with these types of setups. __________________ '06 Lotus Elise (Laser Blue/Black/Sport-Pack/Touring-Pack/Hardtop/TRD airbox/Stage-II Exhaust) - VIDEO

11-04-2008, 10:53 AM	#6 (permalink)
shay2nak I <3 chicken, I <3 liver Join Date: Dec 2003 Location: Land of da 1000 Oaks, CA Posts: 15,042	how much does it weigh? What's the muffler diameter? __________________ save ~10 lbs gain 1 hp EQ: Y=(190X) / (1984-X) where Y is (HP) and X is (lbs) '07 EXIGE S * MY CAR ** VIDEOS! '08 ACURA TSX 6-speed http://www.makeNYNYagain.com

11-04-2008, 10:55 AM	#7 (permalink)
Monsi Statistical Anomaly Join Date: Mar 2008 Location: Kauai Posts: 2,291 Images: 21	would it be possible to make it fit an 08?(central exhaust exit) probably require a slightly different muffler I assume when you say header back you mean you left the stock headers in place __________________ Dude, there's my car!

11-04-2008, 11:18 AM	#10 (permalink)
skibum I approve this message Join Date: Jun 2008 Location: Tucson, AZ Posts: 261	Is this the same Mase that does a lot of turbo S2K AEM tuning? __________________ 2006 Exige - Solar Yellow BWR S/C - Tillet B5 CF seats - Arqray SS single - PPE Header & sport cat - TR Motorsports F1 w/R888's - 1934# 2004 s2000 - 378 whp 295 trq 2005 Mini Cooper S 2008 Honda Fit - 35mpg y0! 1965 Austin Mini w/ vtec

11-04-2008, 11:59 AM	#11 (permalink)
probax Registered User Join Date: Apr 2008 Location: Munich, Germany Posts: 60	The sound is insane but would be much too loud for me. Do you still have neighbours who might complain or are they already deaf I've driven a Quicksilver for some thousend miles. Sound was great but what's really annoying at least on longer trips is the drone inside. Do you have the same problems with this one?

11-04-2008, 12:51 PM	#14 (permalink)
plastique999 Form and Function Join Date: May 2008 Location: Alta Loma, CA Posts: 3,045	Exhaust sounds amazing!!!!...sounds like my Eisenmann Race exhaust on my M6. Is the internal diameter designed for S/C'd cars? __________________ www.FaceNBody.com 2005 Lotus Elise: 2bular decat\GT3 exhaust,HID's,turn signal&rear fins delete, CFside scoops, CFbinnacle,CFcenter console,Zoom CF mirror,APR Aero kit,CF 5-elem. diffuser,Exige mesh,Ohlins DA,RTD brace,RAC 'lites,Toyo R888's,HawkHT10's,CO painted calipers,SS lines,Reverie XC CF seat,Reverie CF steering wheel,Schroth Profi II 6 pt harness,shifter re-Enforcer,Manly mounts, Accusump,Moroso pan,BWR key to BWR S/C! Spec Racer Ford #237

11-04-2008, 02:29 PM	#17 (permalink)
FLuXeXigeS without a Lotus Join Date: Jul 2007 Location: SoCal/AZ/NV Posts: 4,708	any chance you will offer a single tip ??? more pics??? hp gains??? weight reduction or increase??? __________________ -Coi- currently having Lotus withdrawals Facebook \| Twitter \| Pics \| Vids eBay Store

11-05-2008, 10:17 PM	#19 (permalink)
Sh4rkattk A pound at a time. Join Date: Nov 2007 Location: LA SFV Posts: 559	More pics of the muffler please. __________________ 07 Exige S - PhB., TP, TP, LSD, S111 Rear Panel Delete, 2Bular De-Cat, 2Bular 8x24 Burnt GT3, Custom AEM Intake, 6k HID's, Schroth 4pt ASM Harnesses, Milled Steering Arms, Bronze Volk TE37 w/ RE-01R's, Carbon Craftsquare Mirrors, Carbon Front Lip, Benetec Dry Carbon Undertray/Diffuser

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