[avocet]

Originally Posted by CobraMarty

I think you could make it even easier on yourself.

I would only cut open the left 'box' and make the 4 cuts you show to eliminate the 2 90* bends going to the tips. No need to open the center or the right side 'box'.

You might have to put a tack weld on the 2 cut 90* where they exit the divider to keep them from rattling.

Smaller square opening to cut into the muffler, 4 sawzall cuts, 2 tack welds, weld the square back on, done.

That is exactly what I was thinking! Although I do wonder what sort of impact the old man hair has...

Now, it is just getting around to doing it! lol

[Greyfox]

Originally Posted by 330iN52

Internals of european version of PE N52, which basically same as US except it has valve.

I wonder if you cut open a 2006 330i muffler if you would not find the same layout.

[SAMCRO]

Hi everyone,new guy here.Thought I would share my experience of what i did on my 2008 325i.I went and bought a stock E82 135i muffler then did the PE mod before fitting it on to my car. It sounds great for me,its got that refined I6 tone. Drive spiritedly for a while and it starts to pop and crackle on liftoff. Here is a video i took.

[ar_e90]

Originally Posted by SAMCRO

Hi everyone,new guy here.Thought I would share my experience of what i did on my 2008 325i.I went and bought a stock E82 135i muffler then did the PE mod before fitting it on to my car. It sounds great for me,its got that refined I6 tone. Drive spiritedly for a while and it starts to pop and crackle on liftoff. Here is a video i took.

that actually sounds amazing. Do you mind showing what you cut/replaced inside the muffler?

[gqbriel]

Originally Posted by ar_e90

that actually sounds amazing. Do you mind showing what you cut/replaced inside the muffler?

Indeed it sounds wonderful - another request is it possible to share some pics from below the car + the what you have cut exactly .

Did you fit that exhaust :



Thanks

[SAMCRO]

Originally Posted by gqbriel

Indeed it sounds wonderful - another request is it possible to share some pics from below the car + the what you have cut exactly .

Did you fit that exhaust :

[IMG]http://i.ebayimg.com/images/g/A5MAAO...0k/s-l1600.jpg[/IMG]

Thanks

Yes that?s the muffler i fitted. If you cut it open it has 2 pipes inside,1 with 3 big holes and 1 with many small holes. I welded shut the 3 big holes and half the small ones then closed the muffler.The exhaust shop just had to weld 1 extra hanger on the box and it fits nicely on the original mounting points of the E90 muffler. Also had to weld the flap in the open position otherwise it will just rattle. Here is a picture of how it looks inside and where you need to weld. I opened my box only in the middle like the 2nd picture. The other pic is just to see the whole thing. I will also try to take a picture of under the car but its just straight forward swapping the boxes and you also save but a bit of weight as the E90 muffler weighs a tonne.

[TylerJamesInc]

Thanks to this thread, I recently reworked my "N52"(actually an N51, so I can't call it an N52 in good conscience) muffler.
I took a different approach than I've seen anyone else take, and the results are fantastic!
After cutting open the casing, I came up with my plan. I then cut the two ~1.75" tailpipe 90's out, and removed the tailpipes altogether.
I got a 3" 90*, and a 2.25" 180* mandrel bend from a local exhaust supply shop to make my new routing.
I'll let the pics speak for themselves, but it tuned out great. To be clear- all the packing went back in. The new routing is very simple- the 2.75" inlet comes in, goes through the perforated/packed section once, and goes through a custom 3" to dual 2.25" tailpipe y. The 3" worked perfect to slip over the 2.75" lip where it exits the packing chamber, and also wasn't difficult to flatten in order to transition well to the 2.25" y. As you can see, I cut open WAY more than I needed to. My original plan was to try to clone the PE more closely, but after looking at how much fabrication work that would be, I came up with a much easier(and better, IMO) method. If you follow my method, you only need to cut open the tailpipe-side chamber.
2.25" to 3" stainless single wall tips are damn near impossible to find, so I got two rolled edge tips, and cut them to my liking.
Hope this helps a member- or two- with their own N52 muffler chop.
Enjoy!

[TylerJamesInc]

Here's a short little video of the result-

Sorry for the rain noise; it's Oregon
Aside from the muffler re-work, the car is 100% stock. Res still in place.

[CobraMarty]

Nice, you effectively made it a 'straight pipe'.

[TylerJamesInc]

Originally Posted by CobraMarty

Nice, you effectively made it a 'straight pipe'.

Not really. Actually, not at all.
Just like the PE, it still has a perforated section of pipe- with packing around it that absorbs waves- in the center chamber.
I've heard muffler deletes drone, and mine has no drone, so it's still a very effective muffler.

[CobraMarty]

Gotcha, still has about 4-6" of perforated pipe with packing around and chamber.

Nicely done.

[althafazh]

i chopped opened mine gutted the hair thing and cut two holes on the inlet and exit pipes. Exhaust sound is still silent but has more volume on idle when you rev it . its better than stock but i might go and chop the whole piping out idk lol...

[TylerJamesInc]

Originally Posted by CobraMarty

Gotcha, still has about 4-6" of perforated pipe with packing around and chamber.

Nicely done.

Exactly.
And thank you!

Originally Posted by althafazh

i chopped opened mine gutted the hair thing and cut two holes on the inlet and exit pipes. Exhaust sound is still silent but has more volume on idle when you rev it . its better than stock but i might go and chop the whole piping out idk lol...

You really have to re-route the pipes to make it worth cutting open the muffler.

[aluka14]

hey mate, really nice muffler mod you got there however I dont know much about mufflers so can you please tell me if this cutout plan is any good. Any potential problems or incorrect connections? Cheers

[TylerJamesInc]

Originally Posted by aluka14

hey mate, really nice muffler mod you got there however I dont know much about mufflers so can you please tell me if this cutout plan is any good. Any potential problems or incorrect connections? Cheers

Do not do that to your muffler.
You would be effectively necking your exhaust down to a single 2" outlet.
On the stock setup, we have a 2.75" inlet, and dual 2" outlets. By splicing the outlets into one, you're only allowing a single 2" outlet.

[aluka14]

what if i connect the two outlets with a Y pipe, is inlet setup on the other side problematic?

[TylerJamesInc]

Originally Posted by aluka14

what if i connect the two outlets with a Y pipe, is inlet setup on the other side problematic?

I'm gonna be straight up with you- you need to either study the pictures posted more, or just cut one open and figure it out. You need to understand the flow of the exhaust before you start modifying it in completely ineffective- or negatively affecting- ways.
Here's some decent pictures I took-

[gqbriel]

Originally Posted by TylerJamesInc

I'm gonna be straight up with you- you need to either study the pictures posted more, or just cut one open and figure it out. You need to understand the flow of the exhaust before you start modifying it in completely ineffective- or negatively affecting- ways.
Here's some decent pictures I took-

What is your suggestion in order to gain some sound and still keep the muffler operating properly for the car..
Thanks

[TylerJamesInc]

Originally Posted by gqbriel

What is your suggestion in order to gain some sound and still keep the muffler operating properly for the car..
Thanks

Do what I did with the 3" mandrel bent 90* and 2.25" mandrel bent 90* made into a Y.
Copy what I did, and you will have a very good sounding- yet very tame- exhaust.

[gqbriel]

Originally Posted by TylerJamesInc

Do what I did with the 3" mandrel bent 90* and 2.25" mandrel bent 90* made into a Y.
Copy what I did, and you will have a very good sounding- yet very tame- exhaust.

[CobraMarty]

I bought a spare muffler to work on for $50.

I cut open the left side box area where the tips go into.
Cut out the 2 long 90* 1.75" pipes going to the tips.
Ordered a piece of 3" mandrel bent elbow.

Going to flatten out/oval one side of the 3" 90* and split it and slightly widen it to fit over the cut pipe going to the tips.
So one side of the 3" 90* will go to the large 'inlet' pipe in this area. And the other end will be flattened to oval and split and widened to fit over the exit pipes.

It will be like this pic but simpler and I am going to leave the stock tips and short stub pipes inside coming from the tips.

[TylerJamesInc]

Hm, trying to understand how you'll connect the outlets to one pipe without a Y. Will it not quite be sealed to the outlets? Probably fine if it's not, really.

Looking forward to seeing pics! I think you'll be pleased with the sound. It's surprisingly tame, and sounds really good! Not sure how much sound difference my larger outlets make, but I wouldn't think much at all.