Monthly Archives: December 2011

Importance of Mandrel Bends

A well designed exhaust can make a big difference to performance, maintaining velocity of the exhaust gases with as little restriction as possible is the key. The reason is the scavenging effect on your engine. What this means is that with an excellent system, each exhaust pulse, as it races through the piping, leaves a slight vacuum behind it to help suck the exhaust out of the next cylinder when the exhaust valve opens. This helps make your engine more efficient. You want to pump in all of the air you can, and pump all of the exhaust gases out ASAP. This is especially important at high rpm, when things are happening more quickly.
Now, as you introduce restrictions to the exhaust, you begin to reduce the scavenging effect because you don’t maintain the same velocity through the system. Mandrel bends are a great advantage over crush bends as the inner diameter of the exhaust pipe constant throughout the system.

Importance of Mandrel Bends

Mandrel bends maintains the same ID all the way through the bends. Crush bends are just like they sound; the piping is crushed slightly while bending, decreasing the ID of the pipe.

Importance of Mandrel Bends

Mandrel bent is the preferred method, but requires special equipment. Mandrel Bend Equipment is very expensive and most local muffler shops can only crush bend or only have access to pre bent 45, 90, 180 sections in mandrel bends. When building a custom setup ask for mandrel bends.

Importance of Mandrel Bends

Importance of Mandrel Bends

Importance of Mandrel Bends

 

Importance of Mandrel Bends

Xforce Exhaust systems uses mandrel bend in all its exhaust systems, restriction is kept to a minimum while flow and velocity is kept high. With a full Mandrel bend Xforce exhaust system coupled with Xforce headers power gain of 15-35rwkw (FPV FG 335 GT) has been achieved with no other supporting mods.

Importance of Mandrel Bends

For a custom exhaust setup Xforce also offers a universal mandrel bends (15,30,45,60, &90 degree) in stainless and mild steel . Sizes ranges from 1” ½ – 1D bends

Read more http://blog.xforce.com.au.tmp.anchor.net.au/?p=313

Xforce High Flow Catalytic Converters

 

Xforce High Flow Catalytic Converters

What is a Catalytic converter and how does it work?

A catalytic converter is a device used to reduce harmful emissions released from a car’s exhaust. It can be found between the extractors and muffler. Emissions from car’s exhaust consist of noxious gases such as carbon monoxide, hydrocarbons and nitrogen oxide. They are responsible for smog, myriad respiratory problems and damage to plant life.

Emissions pass through a Ceramic honeycomb catalyst structure (normally consisting of a metallic catalysts, platinum, rhodium or palladium) that causes a chemical reaction with the noxious gases, converting them into less harmful gases such as carbon dioxide, nitrogen and water vapors.

Xforce High Flow Catalytic Converters

OEM Cat converters Vs Hi-Flow Cat Converters

OEM type Catalytic converters do a great job at controlling and reducing emissions; however they are restrictive by design (bottle neck inlet/ outlet and a very dense honey comb cell structure). Stock factory cat of Holden VY commodore SS (on one side) has been tested to show a flow rate of 250cfm. Xforce Metallic and Ceramic High flow cats has shown to flow as much as 550cfm for a 2.5″ ceramic cat (400cell), and 750cfm for a 3” metallic cat (200cell as tested). Replacing the factory item for an Xforce High flow racing cat can show a significant increase in Horsepower.

What type of cats you should use:

The two most common used aftermarket cats are: Ceramic substrate and metallic substrate catalytic converters.

  • Ceramic cats in general have lower flow rate than metallic cats.
  • Ceramic cats are more economical while metallic cats cost more.
  • Ceramic cats are ideal for Modest Modifications

 

  • Metallic cats are more durable than the ceramic cats, more shock resistance than the ceramic substrate.
  • Metallic cats can support higher Exhaust gas flow speed and higher exhaust temperature,
  • Metallic cats are ideal for highly modified cars

MIL/ CEL issues

Installing hi-flow racing cats could trigger the CEL(Check Engine Light) or MIL (Malfunction Indicator Light) on the dash usually occurring in later model cars. In Australia, late model cars (2005 onward) are required to have a second O2 sensor located immediately after the factory cat. This allows the ECU to detect any changes in emission condition, malfunction or inefficiency of the cat, unfortunately it also interprets the “hi-flow” characteristic of performance cats as inefficient emission control. If the diagnostic code is scanned by DTC scanner, the code will likely to be something like “P0420: catalyst efficiency below threshold”.

Xforce High Flow Catalytic Converters

“CEL eliminators” are available on the market to help solve this common issue; however it should be noted that they can also produce mix results. A “CEL eliminator” is basically an O2 sensor bung adaptor, which is fitted between a factory O2 sensor bung (seating) and the O2 Sensor. Some have small sections of cat converter fitted inside the tube, some don’t. We found that none of the latter (the one without cats) works so far, while the former one (with cats) work on some cars, but not all of them. They act as “filters” for the exhaust gas before they reach the O2 sensor. After much testing we concluded that the results will depend on how good the small cats inside the adaptor are, and also the sensitivity of the sensor.

Xforce High Flow Catalytic Converters

The best solution we feel to remedy this problem is an ECU tune including a “ECU Flash Tune”, which are available from many performance Workshops.

Hi-flow aftermarket cats have shown to produce significant power gain, especially for high-end performance applications. However this is at the cost of less emission control over the factory stock units, so it only suitable and is advisable for race and off road applications.

 Exhaust Sounds

After installation of a hi-flow cat, there will be much less back pressure resulting in increased gas flow, and sound/noise level. The higher flowing the cat is, the higher the sound level will be. Typically the difference in sound level before and after a high flow cat can be from 2~4 dB for a hi-flow 100 or 200 cell metallic cat.

When planning a new exhaust system, the type of cats should be considered as an important factor that can affect the exhaust sound characteristics. As an example, if your aftermarket cat-back system is too quiet and you are plan to upgrade the system for more noise, you should always try the hi-flow cat first before chopping and changing the mufflers to a louder one (normally the smaller body size mufflers are louder than the large body ones.). This may save you a lot of money, time and hassle. The reverse can also be applied here for a quieting a system (at the cost of some power and flow)

 Maintenance

Both ceramic and metallic cat converters could fail or “melt” under extreme high temperatures. An example is an engine that runs too rich. The excess amounts of un-burnt fuel can get dumped and trapped on the edge of the cat and continue to burn in a very high temperature for a long period of time, which could cause the cat substrate to melt.

The above example is often seen on a dyno runs with newly installed cat (especially with other power supporting modifications). So Extra precaution is required and a must when dyno running a car. Always make sure the air/fuel mixture is right or within reasonable range before a max power run. Maintaining a good engine tune is crucial for the longevity of the cat converters. It’s also important to note that many cat converter manufacturers do not cover warranty for failure due to incorrect engine conditions.

Important note: XFORCE hi-flow catalytic converters are designed for off road and racing use only.

Xforce High Flow Catalytic Converters

Xforce High Flow Catalytic Converters

Read more http://blog.xforce.com.au.tmp.anchor.net.au/?p=303

XFORCE Exhaust systems for Nissan R32, R33,R34

XFORCE Exhaust systems for Nissan R32, R33,R34

Pitcure by:  KSPproductions

Turbo Back System (R32 GTST)

Turbo-Back System components including:

  • 3″ Bell Mouth Style Dumpipe;
  • 3″ Hi-flow Cat;
  • 3″ middle section With Oval Resonator;
  • 3″ rear section with Angle-out cannon Muffler.

XFORCE Exhaust systems for Nissan R32, R33,R34

XFORCE Exhaust systems for Nissan R32, R33,R34
Turbo Back System (R33 GTST)

Turbo-Back System components including:

  • 3″ Bell Mouth Style Dumpipe;
  • 3″ Hi-flow Cat;
  • 3″ or 3.5″ middle section With hot-dog style or oval style resonator;
  • 3″ or 3.5″ rear section With Angle-out Cannon Muffler;Muffler Specs:4.5″ Tip,7″ barrel.

XFORCE Exhaust systems for Nissan R32, R33,R34

 

XFORCE Exhaust systems for Nissan R32, R33,R34

Turbo Back System (R34 GTT)
Turbo-Back System components including :

  • 3″ Bell Mouth Style Dumpipe;
  • 3″ Hi-flow Cat;
  • 3″ or 3.5″ middle section With hot-dog style or oval style resonator;
  • 3″ or 3.5″ rear section With Angle-out Cannon Muffler;Muffler Specs:4.5″ Tip,7″ barrel.
XFORCE Exhaust systems for Nissan R32, R33,R34

Read more http://blog.xforce.com.au.tmp.anchor.net.au/?p=286

XFORCE Exhaust systems for Nissan 180sx, S13, S14, S15

XFORCE Exhaust systems for Nissan 180sx, S13, S14, S15

Picture by: アケミケ

Xforce exhaust systems are designed to be a true bolt-on option and power gainer. All exhaust systems are R&D in-house and dyno tested with proven power gains. 304 Stainless steel mandrel bends, and flanges are used in the construction for its strength, excellent heat resistant, rust proof, high flow (mandrel bends) and finish properties. Everything in the Xforce range includes bolts, nuts, gaskets and everything else needed for a true bolt on experience.

Xforce recommends a dyno tune after an exhaust item has been upgraded (like any other power mod) to fully utilize its power potential.

Turbo Back System(180SX/S13)


Turbo-Back System components including :

  •  3″ Bell Mouth Style Dumpipe;
  •  3″ Hi-flow Cat;
  •  3″ middle section with oval style resonator;
  •  3″ rear section with angle-out Cannon Muffler;
  •  Muffler Specs: 4.5″ Tip,7″ barrel.

XFORCE Exhaust systems for Nissan 180sx, S13, S14, S15

SR20 Turbo Manifold

  • 304 grade Stainless steel
  • 2.5mm thickness,heavy duty design

Options:

  •  Standard Mount: suit standard turbo;
  •  Top Mount: suit T3 turbo with external wastegate.
XFORCE Exhaust systems for Nissan 180sx, S13, S14, S15
XFORCE Exhaust systems for Nissan 180sx, S13, S14, S15
XFORCE Exhaust systems for Nissan 180sx, S13, S14, S15
Picture by:sinoshi_tas
Turbo Back System(200SX S14/S15)

Components of the 200SX S14 and S15 Turbo-back exhaust system:

  • Dump-pipe with separate waste-gate pipe
  • Engine pipe 3”
  • Hi-flow Cat 3”
  • Middle section with oval resonator
  • Two options for rear mufflers
  • Angle-out Cannon Muffler: 4” tip size, 6” barrel size, sitting in slight angel(drift style); Sound level:92~94dB
  • Twin Tip Oval Muffler: Twin 3” O.D double wall resonated tips, straight-out sitting; produce lower sound output.
  • Sound level:88~90dB
XFORCE Exhaust systems for Nissan 180sx, S13, S14, S15
XFORCE Exhaust systems for Nissan 180sx, S13, S14, S15

 

Read more http://blog.xforce.com.au.tmp.anchor.net.au/?p=273

Varex Exhaust sound clip for Hondas

Varex Exhaust sound clip for Hondas

Some sound clips for anybody that might be thinking about going a Varex/ Xforce exhaust. Most of these are customs setup using a Varex muffler.

Let me know what else you guys want and i’ll try find it.

Note: Photo and video clips do not belong to Xforce.

1990 honda integra da9 with a full xforce extractors back exhaust system with varex tip. Varex in “quiet” mode. Headers are 4-2-1 design: 42MM-48MM-60MM. Piping is 60mm with a single 12” resonator.

Watch this video on YouTube.

With Valve open. “Loud” Mode.

Watch this video on YouTube.

 

Varex Xforce on 2005 Civic Sedan

The car is equipped with Vafc 2, DC 4-2-1 Race headers. OEM Intake.

The video demonstrates the Varex model VMK10-250 with on / off electronic silencer.

Watch this video on YouTube.

 

Demo of the xforce varex muffler on a 1994 H23 Prelude, stock engine, custom 2.5 inch pipping from the cat – muffler

Watch this video on YouTube.

Read more http://blog.xforce.com.au.tmp.anchor.net.au/?p=266

Xforce Varex Exhaust System Install

Xforce Varex Exhaust System Install

All Xforce Varex Exhaust systems include every nut, bolt and gasket for a true bolt on experience. With a little knowledge, a spare weekend and some basic tools a home mechanic car enthusiast can easily install, fit and enjoy an Xforce Varex Exhaust system.

1. Jack the car up. Using manufactures jacking points, so 4 wheels are off the ground. Use car stands to hold up the car,( Do not only use a jack on its own, it may fail and the car will fall on you). When using ramps be sure to lock the emergency/Hand brake and block/choke the front wheels. DO NOT USE cinder blocks in any circumstances.

2. Assess the condition of all the parts of your exhaust system before beginning.

3. Lie on your back and position yourself under the car until you are looking at where the pipes bolt onto the catalytic converter.

4. Unbolt the old exhaust system starting from the Muffler and work your way forward to the cat. Generally, the bolts are rusted and hard to get off. Use some WD-40 to penetrate the bolts.

5. Remove all parts of the exhaust you’re going to replace. Remove them from the hangers and set all the old parts aside in order.

6. Remove or cut the old hangers off.

7. Depending on the type of rubber exhaust hangers your car uses, its recommended to put the new hangers onto the exhaust pieces first, this is usually an easier way to put the exhaust parts back on.

8. Check to see if there are any sensors like an O2 sensor or Ground wire.  These may need to be removed. Unplug if necessary. It is generally located near the catalytic converter.

9. Now starting from the front of the car, hang the exhaust part up then bolt it onto the pipe before it, do not tighten all the way until you have all pieces on.

10. Newly supplied gaskets will need to be put in between the pipe segments

11. After all pipes are attached, start tightening each segment. And plug or replace any removed sensors or ground wire.

12. Take a few steps back from the car and make any alignment adjustments you need so that the tailpipes are even with the bumper and looks good.

13. Double check and tighten all the bolts.

14. Start the car up and locate any leaks you may have.

Note: this is only a guide, Xforce do not take any responsibilities for any damage to you or your car. It is also advisable that with any new Xforce Varex exhaust upgrade, a trip to a workshop with a dyno for a retune or flash to the ECU is recommended to fully utilize its performance potential and to check the Air/fuel ratios.

Read more http://blog.xforce.com.au.tmp.anchor.net.au/?p=259

XForce Exhaust systems for 350z and 370z

XForce Exhaust systems for 350z and 370z

XFORCE produces exhaust systems for Nissan’s popular 350z and 370z models. Xforce exhaust systems are designed to be a true bolt-on option and power gainer. All exhaust systems are R&D in-house and dyno tested with proven power gains. 304 Stainless steel mandrel bends, and flanges are used in the construction for its strength, excellent heat resistant, rust proof, high flow (mandrel bends) and finish properties. Everything in the Xforce range includes bolts, nuts, gaskets and everything else needed for a true bolt on experience.

Xforce recommends a dyno tune after an exhaust item has been upgraded (like any other power mod) to fully utilize its power potential.

350Z

Headers

Material: 304 grade stainless steel

Design: 3-1 style

Runner size: 42mm-60mm

XForce Exhaust systems for 350z and 370z

Cat-Back System
304 grad stainless steel, Highly polished, Mirror finish.
Dual 2.5″ Center with even-flow X-Pipe, to dramatically improve power and torque
Twin large-size oval rear mufflers, straight-through internal design. Minimize back pressure, enhance performance
Carefully tuned system with each of the twin pipes loop through both rear mufflers individually, double sound damping effects to reduce unwanted noise range and improve sound quality.
Dual-side oval angle-cut double-wall tip
The 350Z cat back system produces a lower, deep sporty tone
Pipe size: Dual 2.5″ (section area larger than 3″ system)

XForce Exhaust systems for 350z and 370z

XForce Exhaust systems for 350z and 370z

XForce Exhaust systems for 350z and 370z
XForce Exhaust systems for 350z and 370z

XForce Exhaust systems for 350z and 370z

 

 

Watch this video on YouTube.

 

 

370Z

Cat-back system
XFORCE Nissan 370Z Performance Twin 2.5″ Cat-back system, featuring X-Pipe, twin front hot-dog resonator, dual Rear mufflers and dual 4″ tips. The 370z cat back system produces a deep sports tone and maximum performance gain.

XForce Exhaust systems for 350z and 370z

XForce Exhaust systems for 350z and 370z

 

Watch this video on YouTube.

Watch this video on YouTube.

 

Read more http://blog.xforce.com.au.tmp.anchor.net.au/?p=245

XFORCE Exhaust systems for Holden Commodore VT/VX/VY/VZ/VE

XFORCE Exhaust systems for Holden Commodore VT/VX/VY/VZ/VE

Xforce exhaust systems are designed to be a true bolt-on option and power gainer. All exhaust systems are R&D in-house and dyno tested with proven power gains. 304 Stainless steel mandrel bends and flanges are used in the construction for its strength, excellent heat resistant, rust proof, high flow (mandrel bends) and finish properties. Everything in the Xforce range includes nuts, bolts, gaskets and everything else needed for a true bolt on experience.

Xforce recommends a dyno tune after an exhaust item has been upgraded (like any other power mod) to fully utilize its power potential.

 

XFORCE Exhaust systems for Holden Commodore VT/VX/VY/VZ/VE
Cat-Back System(VE SS/Calais/Clubsports R8/GTS/Maloo/Caprice/Statesman)

  • X-Pipe design, optimize exhaust flow and engine performance
  • Oval style resonator and oval style rear mufflers
  • Proven power gains;
  • Design options:
  • Twin 2.5” quiet system: Sound level:Low
  • Twin 2.5” medium system : Sound level:Medium
  • Twin 3” medium-loud system: Sound level:Medium-Hig

Stainless Steel Tip Options:

  • Quad-76mm Tip
  • Quad-80mm Tip
  • Material options:
  • Polished 304 grade stainless steel piping and tips
  • Mild steel piping and stainless steel tips

XFORCE Exhaust systems for Holden Commodore VT/VX/VY/VZ/VE

XFORCE Exhaust systems for Holden Commodore VT/VX/VY/VZ/VE

Header & Hi-flow Cat (VE all models)

  • Fully mandrel bent pipe works & race-inspired merge collectors that optimize exhaust flow and engine performance.
  • Fully TIG welded to enhance durability
  • Proven power gains

Design options:

  • 4 into 1: 1”5/8 primary , 2.5” secondary
  • 4 into 1: 1”3/4 primary , 3” secondary
  • 4 into 1: Step-up (1″5/8 to 1”3/4) primary , 3” secondary

Material options:

  • Polished 304 grade stainless steel
  • Mild steel with silver colour high-temperature resistant paint
  • Hi-Flow metallic racing Cat (For both 2.5” and 3” outlet headers)

XFORCE Exhaust systems for Holden Commodore VT/VX/VY/VZ/VE

XFORCE Exhaust systems for Holden Commodore VT/VX/VY/VZ/VE

Watch this video on YouTube.

 

XFORCE Exhaust systems for Holden Commodore VT/VX/VY/VZ/VE

Cat-Back System(VT/VX/VY/VZ SS Cat-back)

  • X-Pipe design, optimize exhaust flow and engine performance
  • Oval style resonator , and oval style rear mufflers
  • Twin 3” O.D double wall polished stainless steel tips
  • Proven power gains

 

Design options:

  • Twin 2.5” with oval rear muffler: Sound level: Medium
  • Twin 2.5” with hot-dog style rear mufflers: Sound level: High
  • Twin 3” with oval rear muffler: Sound level: Medium-high

Material options:

  • Polished 304 grade stainless steel piping and tips
  • Mild steel piping and stainless steel tips

XFORCE Exhaust systems for Holden Commodore VT/VX/VY/VZ/VE

Header and Cat (VT~VZ V8 5.7L & 6L )

  • 4-1 Header:
  • Option 1: 1” 5/8 primary and 3” collector
  • Option 2: 1” 3/4 primary and 3” collector
  • Tri-Y header: 1”5/8 Primary 2.5” collector

 

Cat Options:

  • Option 1: 2.5” ceramic hi-flow racing cat
  • Option 2: 2.5” metallic hi-flow racing cat
  • Option 3: 3” ceramic hi-flow racing cat(for 1”3/4 header only)
  • Option 4: 3” metallic hi-flow racing cat(for 1”3/4 header only)

XFORCE Exhaust systems for Holden Commodore VT/VX/VY/VZ/VE

XFORCE Exhaust systems for Holden Commodore VT/VX/VY/VZ/VE

XFORCE Exhaust systems for Holden Commodore VT/VX/VY/VZ/VE

 

Watch this video on YouTube.

For more information on Xforce exhausts including installed pictures, sound clips, movie clips and contact details Click Here

Read more http://blog.xforce.com.au.tmp.anchor.net.au/?p=236

XFORCE VAREX Holden Commodore VE SS Sportswagon Performance Exhaust

Watch this video on YouTube.

XFORCE Performance Full Exhaust System for Holden Commodore VE Sportswagon SS and Sedan type.

This full stainless steel exhaust system includes :1″3/4 header and twin 3″ hi-flow racing cats , and twin 2.5″ cat-back system with Varex rear mufflers (in 3″ inlet”).

Varex exhaust creates a quiet , near stock(standard) sound, and hi-performance V8 sports notes with a click of button. A full Varex exhaust system has shown on the dyno to produce significant power gains.

For more info on other Holden Exhaust systems visit :http://www.xforce.com.au/vehicles.php?make=Holden&make_id=5

Read more http://blog.xforce.com.au.tmp.anchor.net.au/?p=228

Varex Sound Muffler Review

Varex Sound Muffler Review

Shot in 2007 in our workshop, (offer in the video in not valid ) Ignition DVD give us a quick rundown on the Varex system on a WRX. In the second clip we get the Mighty Car Mods boys to come over to our workshop for Moog’s Varex installation on his S15. Both clips are shot in our workshop where we design, test and develop all our Xforce and Varex muffler range.

See if you can spot our dyno at 8:11 in the mighty car mods video.

Watch this video on YouTube.

Watch this video on YouTube.

For more info on Varex click here : http://www.xforce.com.au/about-varex-remote-control-sports-muffler.php

Read more http://blog.xforce.com.au.tmp.anchor.net.au/?p=190