New Muffler in Development - LotusTalk - The Lotus Cars Community

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post #1 of 75 (permalink) Old 03-31-2017, 01:05 PM Thread Starter
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New Muffler in Development

We have begun developing a new Elise/Exige muffler with a US mfg that we hope will deliver a unique sound. Much like the Arqray Single Tip, we expect this system to be drone-free yet loud when you are in the higher rpms. This is the Holy Grail for sport mufflers and especially difficult with the Lotus. Usually when it is loud, it also drones or when a sport muffler doesn't drone, it can be too quiet. Our partner will incorporate a Helmoltz Chamber into our system to effectively kill drone. It may take us a few iterations but I'm confident we will land on a sweet sounding muffler as these guys do great work.

I've listened to many, many systems in our cars so have a keen ear - but I will recruit some local owners to get your opinions.

I'll post up info here when I have more to share.
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post #2 of 75 (permalink) Old 03-31-2017, 01:54 PM
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Will they be both s/c and na friendly or will there be different designs for different applications?

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post #3 of 75 (permalink) Old 03-31-2017, 02:19 PM
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and, will it be repackable

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post #4 of 75 (permalink) Old 03-31-2017, 04:37 PM
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This is much needed consumables product beside tires.
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post #5 of 75 (permalink) Old 04-01-2017, 10:17 AM
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post #6 of 75 (permalink) Old 04-01-2017, 10:47 AM
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Originally Posted by A1Harry View Post
This is much needed consumables product beside tires.
Exhaust is a consumable product? Uhhh.... What?!?

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post #7 of 75 (permalink) Old 04-01-2017, 01:12 PM
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What do you think the eta will be?
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post #8 of 75 (permalink) Old 04-01-2017, 01:25 PM
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Exhaust is a consumable product? Uhhh.... What?!?

The ones with glass packing or stainless packing change tone over time at best and need to be re packed occasionally at worst, so yeah, some of them actually do tend to have service intervals or life expectancy. The chambered ones don't have that issue though.


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post #9 of 75 (permalink) Old 04-01-2017, 05:00 PM
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I'll be the guinea pig if you need one Shinoo.
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post #10 of 75 (permalink) Old 04-02-2017, 10:33 AM Thread Starter
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This first system will be an above diffuser exit but we will also do a diffuser exit. This system won't be repackable. We may have different systems based on NA vs SC.

I should have a prototype late this week to test - hopefully. I will post up some info when I have something. Timing for production is TBD. I want to get the sound right first. The aesthetics will then be finalized and then we start production.

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post #11 of 75 (permalink) Old 04-02-2017, 10:35 AM Thread Starter
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I'll be the guinea pig if you need one Shinoo.
Thx, I'll reach out when the time is right.

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post #12 of 75 (permalink) Old 04-06-2017, 04:10 PM Thread Starter
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Picked up the car with the new system and put 3+ hours of driving on her. City, freeway, stop & go and canyons. It sounds properly sporty on the second cam and quiet below that. There is absolutely no drone. 6th gear cruising from 55-80+mph = no drone. If anything, I might want it to be a bit louder from 6-8k rpms.

I posted a quick video on our IG account: HERE

This is the prototype and we need to land on the final finishes - yes it is stainless.

This is a straight through design so will work great with NA or SC.

I'll meet up with some local Lotus guys to get their opinions and feedback...yes, I will get some better videos (in and out of car).

I think we are onto something very special here. Now I need to get more miles on her...
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post #13 of 75 (permalink) Old 04-06-2017, 04:50 PM
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Will there be a diffuser-exit option?

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post #14 of 75 (permalink) Old 04-06-2017, 06:56 PM
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Will there be a diffuser-exit option?
already answered above

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post #15 of 75 (permalink) Old 04-07-2017, 06:47 AM
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already answered above
Thanks, apparently reading is hard

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post #16 of 75 (permalink) Old 04-07-2017, 07:16 AM
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It looks good Shinoo but I wish you would develop and build a titanium above the diffuser exit, that is repackable. Just like most aftermarket sport bike mufflers.
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post #17 of 75 (permalink) Old 04-08-2017, 11:12 PM
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Holy hell I would love to see this happen. I presently have a Larini, and the boominess and droning are aggravating.

Thoughts on what the price point for this would be?

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post #18 of 75 (permalink) Old 04-10-2017, 08:11 AM Thread Starter
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It looks good Shinoo but I wish you would develop and build a titanium above the diffuser exit, that is repackable. Just like most aftermarket sport bike mufflers.
Ti systems are great - we used to sell the Arqray. We will look at repackable systems in the future.

The repackable systems made by Burns Stainless are light but the repacking is a real pain in butt for most people. The fact that those systems get really loud as the insulation burns up also makes it less desirable for most of the market.

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post #19 of 75 (permalink) Old 04-10-2017, 08:22 AM Thread Starter
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Holy hell I would love to see this happen. I presently have a Larini, and the boominess and droning are aggravating.

Thoughts on what the price point for this would be?
The Larini 8" is the only Larini system that does not drone but some people find it to be too quiet. I think we have found the right combination with this new muffler.

The price point is still getting worked on based on the final design. For example, if we choose to Tig weld the muffler, the labor cost is 10X the cost of Mig welding. We need to decide if we should brush or polish the can and what type of tip we should offer. We have some work to do...

Yes, we will have both above diffuser and diffuser exit options. Initially, we will start with above diffuser.

Here's another quick video: HERE
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post #20 of 75 (permalink) Old 04-13-2017, 12:06 PM Thread Starter
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Here is a 'better' video of the muffler: HERE This video has some in & out of car clips. Check it out.

I drove it for several hours of canyon and freeway driving. The sound is spot on. The prototype weighed 15.5lbs - which is very light.

We pulled it off the car today and sent it back to our partner. They need it to build the production fixture and finalize the first article. We will then confirm fitment in about 2 weeks. I will get them to sort out a diffuser exit solution at that time. I've decided to go with the MIG welded version along with a brushed finish. We may offer a fully polished option if enough people ask for it. Polished systems are getting pretty common so we are going to try a different look. It won't be the first time I break from convention...

If we are lucky, production parts will arrive in late May/early June.

I think we've found the right balance of sporty, drone-free sound in a light-weight, straight through muffler.
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