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      09-16-2012, 09:58 AM   #23
ShocknAwe
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Subscribed for more details, pictures and sound clip!

Custom Hartge-style exhaust for less than 3k? I'm totally game. My wife is probably going to be a little upset with me if it ends up costing over 1k. Gotta figure a way to make it up to her. Haha
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      09-17-2012, 04:09 AM   #24
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Time for pics?
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      09-17-2012, 08:13 AM   #25
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Quote:
Originally Posted by JamJay View Post
Time for pics?
Haha! alright here are a few. sorry, the install is only taking place tomorrow so I will re-post when I have those pics...

This is mainly the exhaust itself and the diffuser mod

First few pics are of the axle-back custom exhaust (2-piece). This is EXACTLY as I wanted it. What you will notice is that the pipe leading into the muffler was split into two and that the muffler has 2 inputs and 2 outputs directly opposite each other. I specifically requested this as that allows HALF the airflow to enter each side and exit each side. This is to give both the left and right sides as equal a flow as possible, so none of that massive flow one side, teeny weeny bit other side story - well, hopefully not anyway. will find out soon. This is different to most of the other designs for the 135i that I've seen which have a tiny pipe going to the right to feed both outlets there. I think the genuine Hartge is the only one that's similar to mine?
Mine is a full stainless system with the welds not ground down. It's a bit dirty as the exhaust was only just made before I took the pics. Will be cleaned and polished before mounting. Tips are 76mm I think? Decided against the 80mm blue titanium. wanted the s/s to stand out.

Onto the diffuser.
If you look at the pic of the fitting side of the diffuser you will notice the 6 white metal tabs at the top edge. These tabs need to slot into slits in your bumper. The guy manufacturing the diffuser (un)kindly placed them but in the incorrect spots, some were off by a whole CM or more. They are only held in by a powdery resin of some sort - required some chipping at with a chisel to get it off, and reposition (I had to create two extra tabs as 8 are needed in total) and then glue them on with fast-set epoxy. It helps to have a dad who used to restore cars as a hobby, helping out. Maybe get one of those, if not, and you're handy enough, just DIY, or get a body shop to do it. Though a few tips, when marking where to reposition the tabs, place the diffuser on the bumper, do not click it in fully, just drop it down a tad to check where the slits are and mark that on the diffuser with a white milky pen or masking tape. MAKE sure to remain parallel with the cars long axis (front to back) when doing this as if you move your head with the curve of the diffuser, you will inevitably incorporate error of parallax into the markings, and they can be WAY off, almost by a whole CM once again, so remember to just keep looking FORWARD when doing the marking, don't turn your head. And keep the tabs narrow, the ones on the diffuser are about twice as wide as they should be.
Once marked, you can start placing the tabs and epoxying them. Sorry I forgot to take pics after I had epoxy'd the new tabs.

Also, there is one small plastic under-tray on the car which will need to be removed, it is toward the centre, and is quite obvious which one, as the diffuser fits in its place, and the other slightly larger tray at the right side, needs to be cut to allow the pipes on the R side to exit, though your exhaust shop might naturally do this for you anyway. these pics are also included below.

lastly, one other tip - in order to support the pipes on the R side, your exhaust shop might weld a bracket onto your chassis like they did on mine (which they matched with an OEM like rubber mount). but that weld is not covered with paint, so I sprayed some Tectyl onto it (brown stuff) to prevent rust in future, just thought you should look out for that and cover that area up if yours is exposed.

That is all for now, will post up when the install is done. If you have any questions just ask away. Happy to help.
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      09-17-2012, 08:44 AM   #26
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It's a little work for sure but really impressed so far, well done and good on you for pioneering it. I like the idea of twin inlet/twin outlet with robust tubing feeding the secondary tailpipes. Good job with the flanged secondary tailpipes too, that'll make adjustments a lot easier.

In for the sounds clips now
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      09-17-2012, 09:03 AM   #27
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Wow, looks great actually.
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      09-17-2012, 09:10 AM   #28
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Yeah the 2-in-2out design I just had to have. If I had had any other design I'd be driving along and be worried to floor it, all the while thinking dam, It must be pouring out smoke from one side and just a tiny bit the other, looking stupid. But now I can just floor it whenever. I'm a bit obsessive like that...

It is actually really easy to mod the diffuser. I'm quite sure anyone around this forum who has done any DIY before could do this in half the time I did. I am just, as I said, obsessive and probably make a task more difficult than it's meant to be by being so picky.

Well hope that gives you all an idea of the exhaust design. The test fit of the diffuser was actually amazing I simply cannot wait for the exhaust to be bolted on tomorrow.
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      09-17-2012, 09:35 AM   #29
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In for a sound clip. I want to do a custom setup as well. Do you know what model Magnaflow muffler that is? Make sure to post pics of it all mounted up as well.
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      09-17-2012, 10:06 AM   #30
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Quote:
Originally Posted by kb135 View Post
If I had had any other design I'd be driving along and be worried to floor it, all the while thinking dam, It must be pouring out smoke from one side and just a tiny bit the other, looking stupid. But now I can just floor it whenever.
This is what initially worried me about a quad set-up. I now know what I need to do haha

Thanks for making this thread and taking the plunge on that diffuser.
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      09-18-2012, 09:12 AM   #31
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Exhaust and diffuser fitted!
No washing/cleaning has been done since so it is still dirty/unpolished. Will be done soon. But still, I am very pleased with the result! Needs minor adjustment to the placement of the added pipes, but its REALLY minor and only because I'm obsessive.

Sounds great too! sorry I dont have a clip up just yet, but will do in the coming days. to describe it, it's very much like taking the stock sound, making it 20-25% deeper and about 20% louder and also adding a tad bit more let-off burble which is slightly more pronounced. I enjoy it. to start off with, the stock system has a bit of "drone" if you want to call it that, while cruising in gears 4-6 at around the 2000 rev mark. that is a bit more noticeable with this system, but not something that bothers me. Although I am very accustomed to the highly tuned, raspy sound of a Golf R32 so I am a little biased, even the stock 135i sound was not really impressive after stepping out of the Golf - rather bland in my opinion. But the 135i on it's own does sound lovely, and smooth, when not comparing.

In any case, I did this mod for appearance, not sound, as I always knew a turbo engine will never give me back what I miss most about my Golf.

Also, for those interested, the Magnaflow muffler part number is 14378.

Edit: by the way, flow on both sides seems equal :-)

Enjoy!
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Last edited by kb135; 09-18-2012 at 09:13 AM. Reason: flow
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      09-18-2012, 10:20 AM   #32
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Looks good! thanks for the muffler p/n! Can you take some pics further back from the car, please? The hartage diffuser moves the tips more inward like the M3, right?
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      09-18-2012, 07:08 PM   #33
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Hi

What is the total cost to run this setup including parts and labour?

Thanks.
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      09-19-2012, 07:47 AM   #34
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Sure I will take a few more pics from further back once I get a chance soon. Yes this is along the lines of an E46 or E90 M3. Perhaps in the meanwhile this image will help you? http://www.seriouswheels.com/pics-20...r-1024x768.jpg

Or this image: http://www.bello-auto.ru/upload/iblo...25696476cb.jpg

Total cost for this setup was:
diffuser + gloss black paint + postage = ~$280
exhaust + install = $1100
Epoxy = $6

UPDATE:
By the way, regarding the sound, remind me to never judge an exhausts sound with the rear seats down! I totally forgot they were still down when I was critiquing the sound and that's what caused all the drone! So, to correct myself, in terms of drone, it is only marginally louder in the 2000 rev range just as the stock system is in that rev range, but not so as to be annoying to me at all. it is definitely about 25% louder all through the rev range, and kind of reminds me, subtly that this car is tuned. it is definitely less muffled now, sounding exactly as i hoped it would, and as I think a car of this calibre should have come from factory. The turbo burble at let-off is more pronounced.
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      09-19-2012, 10:03 PM   #35
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The fitment looks as good as my auth hartge diffuser! I am so sad that it only cost less than $300
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      09-22-2012, 11:11 PM   #36
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Wonder if your exhaust shop would be willing to build this for sale or share the plans.
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      09-28-2012, 05:53 AM   #37
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I can ask him about making a system up and selling it? Not sure about postage cost though that might be a deal breaker considering size/weight?

Yeah I'm quite happy that didn't cost too much to get done. left more funds for the go-fast bits coming from Stu :-) due to arrive soon
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      09-28-2012, 06:02 AM   #38
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You know, I had completely missed that you are in Australia. Definitely not going to be worth it. Too bad.
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      10-19-2012, 04:35 AM   #39
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Please make some sound clips

Which brand muffler is this
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      10-24-2012, 12:25 PM   #40
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Any sound clips yet? its a magnaflow 14378 muffler. Says so in his posts
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      10-26-2012, 03:46 AM   #41
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Sorry guys I've been a little occupied lately and havn't had time for the 1. My brother was going to help me out with filming a sound clip, but he is also occupied. I will have one up within the coming weeks. really sorry for the delay.
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      11-10-2012, 12:40 AM   #42
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Anyone know if these diffusers fir 128 rear bumpers?
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      11-10-2012, 03:03 AM   #43
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Yes they will but only if 128i is M-Sport.
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      11-11-2012, 05:32 AM   #44
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Video clip?
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