- Nov 12, 2009
- 368
- 268
I wanted a louder sound as well, but before I spent a bunch of cash on a new system, I did the OEM muffler modification. This made the mufflers have a better tone, and slightly more volume (approx. 15%).. It's nothing like a Corsa, but I like it as is. We do a lot of road trips, so I wasn't interested in a very loud sound for hours of driving on some days.
This is not for everyone, but it is a simple and cheap mod, using a 3/4 - 1" steel hole saw cutting through the muffler and through the outlet piping about 2" before it exits the muffler into the tail pipe. (see the attached diagram of cut out muffler). The red dot signifies where to drill through the pipe. This can be done from under the muffler. I don't have a pic of the welded cap-painted portion of the finished muffler, but I can get one if some wants to see it.
I went with a 3/4" hole, put a 1/2' electrical panel SS plug to cover the hole just to see if I had enough sound to satisfy me. If not, I would of drilled a 1" hole. I found that I was satisfied with the 3/4 " hole, so I got a 1/2" SS hole plug welded on top of the hole, grinded the weld to make it pretty, and painted that part of the muffler with flat black high heat paint. I've never had any issues passing the yearly vehicle inspections.
This is not for everyone, but it is a simple and cheap mod, using a 3/4 - 1" steel hole saw cutting through the muffler and through the outlet piping about 2" before it exits the muffler into the tail pipe. (see the attached diagram of cut out muffler). The red dot signifies where to drill through the pipe. This can be done from under the muffler. I don't have a pic of the welded cap-painted portion of the finished muffler, but I can get one if some wants to see it.
I went with a 3/4" hole, put a 1/2' electrical panel SS plug to cover the hole just to see if I had enough sound to satisfy me. If not, I would of drilled a 1" hole. I found that I was satisfied with the 3/4 " hole, so I got a 1/2" SS hole plug welded on top of the hole, grinded the weld to make it pretty, and painted that part of the muffler with flat black high heat paint. I've never had any issues passing the yearly vehicle inspections.
