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914World.com _ 914World Garage _ Boxster muffler install
Posted by: toon1 Feb 26 2011, 10:26 AM
This project(like all the others) has been on the "to do "list for awhile.
The mufller fits in the stock location pretty well even with the heat shield in place. If the heat shield was removed, it can go a little higher towards the trunk.
I decided to go all stainless , which aint cheap, but will pay off in the long run.
After all the hard work, I fired it up last night and I have an exhaust leak at the heads. It was 11pm so I shut the garage door and went to bed.
I'm going to chase it down today.
Here are soem pics.
The first two show the hagers that need to be cut off. there are two on top that are threaded studs and to hangers on the back.
Attached image(s)
Posted by: toon1 Feb 26 2011, 10:28 AM
few more
Attached image(s)
Posted by: toon1 Feb 26 2011, 10:29 AM
I will take a few more pics of the how the final installation looks today. 
Posted by: PanelBilly Feb 26 2011, 10:44 AM
I'm just wondering why you chose to put this muffler on
Posted by: ConeDodger Feb 26 2011, 10:57 AM
Cool project... As I recall from my Boxster that muffler is kind of heavy but pretty neat application of the new on the old.
Posted by: toon1 Feb 26 2011, 11:03 AM
I'm just wondering why you chose to put this muffler on
Cool project... As I recall from my Boxster that muffler is kind of heavy but pretty neat application of the new on the old.
I like the way it looks with the center outlet it's also a lot more quiet.
Yes the muffler is heavy but not much more than the bursch collector and muffler assembly. The SS he's are quite a bit lighter than the stock steel HE's .
The assemblies are probably withing 5lbs of eachother.
Posted by: ConeDodger Feb 26 2011, 11:52 AM
So it's a wash. Very cool
Posted by: PanelBilly Feb 26 2011, 12:52 PM
Just wondered. It looks cool
Posted by: gothspeed Feb 26 2011, 01:36 PM
Looks good ! I too prefer a quieter exhaust ......... looking forward to sound clips when you get it done!!
Posted by: Cap'n Krusty Feb 26 2011, 02:09 PM
Excuse me? How is a 40 pound Boxster muffler "within 5 pounds" of a Bursch collector and muffler, which must weigh 15-20 pounds, tops?
The Cap'n
Posted by: raw1298 Feb 26 2011, 04:16 PM
I will be doing the same with my car. Can't wait to see the final product. Did you fabricate a new hanger that works with the studs on the muffler? Lots of pics please!
Posted by: DanT Feb 26 2011, 04:36 PM
have to agree with the Cap'n.
Boxster mufflers are HEAVY. After removing and installing aftermarket mufflers on several Boxsters, the Box muffler has to weigh at least 15-20 pounds more than a stock Banana, and probably more than that over a Bursch.
They give a great look to the rear of a 914, but don't think you are going to save weight doing it
Posted by: Dave_Darling Feb 26 2011, 07:35 PM
Excuse me? How is a 40 pound Boxster muffler "within 5 pounds" of a Bursch collector and muffler, which must weigh 15-20 pounds, tops?
You misread him. He is saying that (Box muffler + SSI) = (Bursch + stock exchangers + 5 lbs).
I don't know that the SSIs are 20 lbs lighter than the stock HE's, but if they are the math can work.
--DD
Posted by: majkos Feb 26 2011, 08:32 PM
Excuse me? How is a 40 pound Boxster muffler "within 5 pounds" of a Bursch collector and muffler, which must weigh 15-20 pounds, tops?
You misread him. He is saying that (Box muffler + SSI) = (Bursch + stock exchangers + 5 lbs).
I don't know that the SSIs are 20 lbs lighter than the stock HE's, but if they are the math can work.
--DD
Them stocks are HEAVY!I think it's a kool project! TWO thumbs up
Posted by: zambezi Feb 26 2011, 11:15 PM
If you guys don't mind looking at another take on this same setup I will show you how I did mine.
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Posted by: zambezi Feb 26 2011, 11:16 PM
Another view
Posted by: zambezi Feb 26 2011, 11:17 PM
View of the collector
Posted by: zambezi Feb 26 2011, 11:18 PM
View of the mounts
Posted by: zambezi Feb 26 2011, 11:21 PM
Test fit into car. I removed the heat shield as I wanted it as high as it could go.
Posted by: zambezi Feb 26 2011, 11:24 PM
I like the look of a low rear valance to give the car a lower look and hides the muffler too. But I was concerned of the heat of the engine getting trapped behind it so here is my valance to go along with my boxter muffler.
Posted by: zambezi Feb 26 2011, 11:27 PM
and finally a side view of the valance. The valance is basically a stock early low valance that I cut down the middle and added 2 inches to. The grill material is the stock engine grill cut to fit. 
Posted by: raw1298 Feb 27 2011, 09:41 AM
Thanks for the pics. Both of these installs look great. Gives me a good view of what I need to do to get everything prepared. Less trips to the parts store.
Posted by: majkos Feb 27 2011, 11:57 AM
I want to hear it!
I bet it's gonna sound kool!
Posted by: McMark Feb 27 2011, 12:10 PM
Cool! I've got a Boxster muffler sitting around that I've been debating installing. They are quite heavy. My unit (stamped 986/54) weighs 30-32lbs in stock/original form. The Bursh I have sitting in the corner weighs about 19 lbs. So you're only looking at about 10lbs difference.
Posted by: toon1 Feb 27 2011, 12:33 PM
Hey zambezi, I like the way you did yours. I especially like the hangers.
In retrospect. I maybe should have mounted it a little higher. I have a fiberglaas rear valance that is about 5.5inches deepso it will cover it nicely
Guy's, the mufflers sound really cool. It's a nice deep thoaty tone.
I've been chasing an exhaust leak at the head, I almost have it fixed and then I will try to get some sound recorded for everyone
Posted by: Jake Raby Feb 27 2011, 12:58 PM
We plan on making a production unit sometime soon that works in a similar manner, using an aftermarket Boxster muffler.. They are 1/2 the weight, sound better and make better power.. Doing parallel development with the Boxster/996 and 914 engines does have some major developmental benefit!
Your set up looks good and retains heat.. Some more defined 2-1 collectors would have helped a bit..
Posted by: Al Meredith Feb 27 2011, 01:54 PM
On the Boxster muffler subject. I have a 2.5L 99 Boxster and will be upgrading to a 2.9 L ( 2.7 crank and L&N big bore ) I just picked up a 3.2 L "S" muffler. Is there any difference in a 2.5 L and a 3.2 L ?
Posted by: zambezi Feb 27 2011, 01:59 PM
I believe the s muffler will have a dual outlet as apposed to the single large oval outlet.
Posted by: Woody Feb 27 2011, 02:29 PM
Muffler is the same, just a different tip.
Posted by: Phoenix-MN Feb 27 2011, 02:39 PM
Here's a video clip of my Boxster muffler (on a V6) I do like it's sound
http://www.youtube.com/watch?v=P2ZUpPduyCE&feature=player_embedded
Posted by: gothspeed Feb 27 2011, 04:34 PM
Here's a video clip of my Boxster muffler (on a V6) I do like it's sound
http://www.youtube.com/watch?v=P2ZUpPduyCE&feature=player_embedded
Sounds good
!
Posted by: Jake Raby Feb 27 2011, 05:53 PM
Al, there are internal differences in the S muffler as well.. Last year we picked up 4RWHP from Charles' Boxster after building a 2.9 for it by changing from the standard muffler to the S muffler. We also saw that on my bone stock 2.5 engine in the old test car.
Posted by: toon1 Feb 27 2011, 06:40 PM
I got the exhaust leak fixed on took the car for a drive.
It is really cool. with the center exhaust outlet, there is far less exhaust noise. The cabin seems to be quieter( may be my imagination).
again, the tone is really nice.
And yes......there is a performance GAIN! I noticed it right off the bat. the car accells much smoother and is more responsive.
I am still working on getting some sound bytes...
Posted by: NS914 Mar 28 2024, 10:06 AM
This project(like all the others) has been on the "to do "list for awhile.
The mufller fits in the stock location pretty well even with the heat shield in place. If the heat shield was removed, it can go a little higher towards the trunk.
I decided to go all stainless , which aint cheap, but will pay off in the long run.
After all the hard work, I fired it up last night and I have an exhaust leak at the heads. It was 11pm so I shut the garage door and went to bed.
I'm going to chase it down today.
Here are soem pics.
The first two show the hagers that need to be cut off. there are two on top that are threaded studs and to hangers on the back.
Hey Al, did you ever get a so7nd byte for this install? I am looking at exhaust opinions now and the Boxster Muffler might really do it for me. I would love to hear it if you still have the car.
Posted by: krazykonrad Mar 28 2024, 02:14 PM
Apart from the sound, is there any benefit to going with the Boxster muffler?
Posted by: SirAndy Mar 28 2024, 04:51 PM
Apart from the sound, is there any benefit to going with the Boxster muffler?
It adds an ungodly amount of weight to the very rear end of your car.
Not exactly sure i would call that a "benefit" though.
PS: Also, this thread is 13 years old
Posted by: raw1298 Mar 29 2024, 06:16 PM
Sounds awesome.
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Posted by: r_towle Mar 29 2024, 06:36 PM
@http://www.914world.com/bbs2/index.php?showuser=1753 might want to give you his once per decade opinion
Posted by: targa72e Mar 31 2024, 10:56 PM
From what I have researched when I was looking at purchasing a Boxster several years ago the mufflers are pretty efficent in that most aftermarkets do no make significantly more power. I have a Boxster S muffler sitting in the corner of my garage awaiting testing. Should be said I only have -6 (914 and 911) to work with. I dyno almost every modification I do to verify if its worth doing.
That said for a small 6 a early 911 muffler (2 in) converted to sport with to two center outlets is within a couple HP of megaphones. Only downside is that is quite loud.
I am expecting that a Boxster S muffler made for a 2.5 six with 250HP will make similar HP and be much quieter then sport muffler I am running now. When I get around to testing I will post the results.
-Some other recent dyno testing I have done on small -6 engines.
https://forums.pelicanparts.com/porsche-911-technical-forum/1151593-dyno-summary-testing-early-2-4l-2-5l.html
I bet that these muffler made to work on newer cars with 200-250 will work good on 914's making 100HP. They might be 10lbs heavier but that is nothing compared to the lightening most Driver could do to themselves (i am in this camp) 
john
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