Bora w/R32 exhaust - flapper mod?

[Dyldo]

Well, just got back from the exhaust shop doing the fitment. They seem quite good, and very helpful. Open to me swanning into their workshop at 7pm at night as they're closing and bothering them with questions, so nice guys.

They called this morning to clarify the work to be done. They say they need new mounting points and that's fine. They say they need to extend the tips and change thedistance they are apart to fit symmetrically and that's also fine. They need to extend the pipe ahead of the centre res to join the catdue to the Bora's length and thats also fine too

BUT they say there is a "chassis rail on the right hand side behind the valance" which will be visible if they cut it for the equidistant right tip. Didn't sound right to me, as I thought there was nothing behind the valance? So I said put the Bora aside and I'll swing by tonight and check it out.

Well, I forgot my camera to take pics to help the thread, but turns out the "chassis rail" bit is actually the rear tow receptor (where you screw in the reverse-thread tow eyelet) and seems pretty damn structural to me. Its on the driver's side, just inboard of the driver's side chassis rail for the rear bar. And they're right, if the stock cutout is copied over to the other side in full, you might see this chassis part.

Sorry, its not too great an explanation without pics. Pics or ban, pics or ban, pics or ban

So, I've asked them to mount the tips to the outermost part of the stock cutouts and see how that looks, and hope it clears the chassis tow bit. The offcuts from the valance I might use as blanking plastic if it all goes the Way of the Pear.

Interestingly though, all these rumours about an R32 system not fitting a Bora because of the spare tyre well and cutting the floor pan and blah blah are definitely dispelled now. Even the back box is relatively easy to fit in the stock heat shield. The mount points need to be bent a bit but a simple job for a zorst shop. I think this will work quite well.

Cat was checked as OK, wasn't blocked and appears to have some catalyst left.

Leaving the centre res in for now, and might remove it in favour of a smaller one with more throughput later if needed for more auralness

Lastly, the flapper. instead of tack-welding it open (rather permanent) they'll be rigging up a combo of wires and some sort of manual switch that I can flick if needed. As in, if the wife starts whingeing and she needs to drive it or something, I can flick it from either inside the boot (preferred) or underneath the car. Flapper open baby
Remember i don't want a turned down tip, and want the two tips on either side of the bumper, r32 style. thoughts?

[graeme86]

Ahhhhhh....that would explain why the R32 doesnt have a rear tow eye then. Often wondered why.

I suppose a GT3RS style twin centre exit would not be considered?

I think most people run the two pipes to the existing outlet on the left.

Decisions, decisions.....

[Dyldo]

i changed to the R32 for a few reasons; heard it was better flow, especially with flapper open, i get burbles and farts on over-run, nice chrome tips, and i like the double outboard look of the tips.

I'd probably prefer to keep the R32-look and it will enable me an easier transition to the Chinese R-Line rear bumper. Although, your twin centres is interesting. Do you mean even closer together than the Mk5 R32?

[graeme86]

The Chinese Bora R only has a single tip on the left. (it was only a 1.8T)

There was a Japanese company making a rear bumper with the twin outlet rear exhaust I think.

GT3RS is right next to each other in the middle:

[qsilverza]

I have the solenoid and green reservoir for and some vacuum piping I used for mine. I never got it to work fully but thats because I didnt have time to stuff around with it once I got it all in. Thanks to graeme for his help with this ages ago. Let me know if you are interested in them.

And yes, maybe I wasn't clear in my original thread but the R32 exhaust definately mounts just fine on the Bora just as you say needs the extra bits way better than the money milltek wants.

Also as per my comments in sales and my r32 exhaust, the best I thought was to have the R32 exhaust with centre res but I loved it without as well so I left it without and used the flapper to quieten it down when I got annoyed or didnt feel like driving aggresively as the centre res removes a lot of the Vring at about the 2 K mark but it also sounds awesome at 4500 I do have a video of me playing in the citylink tunnels

[Dyldo]

She's all done and ready to be picked up. Can't wait to give it a run.

Kept the two tips outboard rather than stock Bora look, or the single tip as dump-pipe, or the centres like Mk5 R32 or 911. the guy says it looks good and "has a definite note to it".

Tacked the flapper open too cause i know i won't be bothered switching it open and closed by hand - i mean really, whats the point?

Kept the centre res in for now, and its a 15 min job for him to bump the res out if i need it gone.

Also, a nice bonus, we removed the triangular "squished" tube just after the centre res and got a 2.5" pipe put in place - has to be better flow right?

Will post photos and videos tonight. I didn't get a before video cause i figure you all know what a stock Bora exhaust is like.

[Dyldo]

its fitted, and looks awesome. here's some piccies





the sound is a different story. I had high expectations, as i guess anyone could figure out from me being so excited. I knew the 3.2L versus the 2.8L would always produce a slightly different sound (deeper for a R32 i'd be guessing) but figured i'd get the same burble and crackling on the over-run. I don't think thats the result i got...

I am fairly sure the flapper is tacked open, but need to take a pic and confirm via here. on start-up and revving (1k rpm to about 3k rpm) everything is quite R32-like and awesome. evil-ish burble and throaty. but after that it sounds similar to the stock unit.

Inside, quite surprisingly, there is no change. yet to do a proper bum-dyno test. maybe can sense a bit of a "Vring" in the midrange but very much like the good ol' Bora - not such a bad thing. No reportable drone at all, and i covered all speeds. tyre noise is actually more annoying than anything.

Need to post video.

Edit - oh, and no cracks about the car being dirtier than a Vegas call-girl on rent night, i just haven't had time BUT i have bought tonnes of stuff from CCP to make her clean

[goodfella]

Its dirty.. clean it!

[Manaz]

Its dirty.. clean it!

And use two hands on that camera!

[Dyldo]

all in good time. dirty things are good too

found a great post - exactly what i was looking for. someone to visually show me what the actuator bar looks like if the flapper is open.
Flapper mod

i will check and verify with a photo tomw, but i am pretty sure they pulled the bar in and tacked it. so flapper mod should be done.

[Dyldo]

And use two hands on that camera!

that was my crackberry - takes surprisingly good pics.

[graeme86]

The default position is open. The vacuum pulls the flap shut (i.e quiet).

So there should have been no need to tackweld anything.

If you want to get rid of the double width exhaust cutout on the left, you should be able to get a diesel rear plastic skirt and cut your exhaust holes to match.

[Dyldo]

oh man, thats awesome. the zorst shop said they'd break the tack if i wanted so no issue there. I just thought the "vacuum" we were referring to would draw the flapper open.

also in all my searching i didn't realise about the diesel rear valance. i was searching for 2.slow and V5 ones. bummer. I can live with the cutouts for the moment.

[graeme86]

I was trying to find some pics of a diesel to double check, but I'm pretty certain they have a hidden exhaust on them.

[Dyldo]

exhaust has to be dumped down for the flapper to be "un-tacked" and therefore (i presume) left open forever - or until i add a solenoid... so i will be waiting till wednesday to free the flapper goodness from the zorst. its the first chance the shop will have free to do it. thats fine by me.

Either way, here is my first vid - its a cold start and i didn't rev much as my family was still sleeping.

YouTube - Bora V6 4Motion w/ R32 exhaust