i86hotdogs Posted July 18, 2019 Share Posted July 18, 2019 Hey Gang, I've searched here, other forums, facebook groups, parts sites, pretty much everywhere but my own vehicle. I've got the 2.5 Duratec in my '16 LWB cargo, and trying to figure out the diameter of the exhaust pipe. My gut leads me to 2.25". Any help from you all would be great. RallyVan for your time. Quote Link to comment Share on other sites More sharing options...
Fifty150 Posted July 19, 2019 Share Posted July 19, 2019 I think it's 2.25". Although I haven't crawled underneath to measure it either. i86hotdogs 1 Quote Link to comment Share on other sites More sharing options...
stanger_missle Posted July 20, 2019 Share Posted July 20, 2019 Yep, Fifty150 is correct: Are you trying to find an aftermarket muffler? The stock muffler is a goofy same side in-out design: You might be able to find something like a straight-thru style muffler and have a few small bends. Here is a shot from the tailpipe back to the muffler. You can see how close the pipes are: Quote Link to comment Share on other sites More sharing options...
stanger_missle Posted July 20, 2019 Share Posted July 20, 2019 Here is a diagram of the exhaust system: Quote Link to comment Share on other sites More sharing options...
Fifty150 Posted July 21, 2019 Share Posted July 21, 2019 I'm looking at that diagram. Part 6 & 8 could be deleted. Replace it with a straight pipe. No muffler. A turn down tip, just like the OEM design, would direct the noise at the ground, so that you bother people with a lot of noise. If you did not have the spare tire, you could install a glass pack to make the exhaust note sound nice. Quote Link to comment Share on other sites More sharing options...
Fifty150 Posted July 21, 2019 Share Posted July 21, 2019 https://www.summitracing.com/parts/sum-640022-1?rrec=true Summit Racing® Exhaust Tubing SUM-640022-1 $12.99 https://www.summitracing.com/parts/svr-xtd214/overview/ Silverline Exhaust Tips XTD214 $13.99 Quote Link to comment Share on other sites More sharing options...
i86hotdogs Posted July 21, 2019 Author Share Posted July 21, 2019 Thanks for all the help! I took an angle grinder to the section circled below. So I already got rid of that gigantic muffler. The sound is ok, but it sounds more accidental than intentional. Meaning it sounds like the muffler's gone bad. I was going to remove the giant resonator (1) and see how it sounds. If I don't like it, I've researched aftermarket mufflers that make 4 cylinders sound decent. I know not all 4 bangers are the same, so I made sure to listen to a few different kinds to get an idea what might come out. I narrowed it down to a Borla Pro XS. I heard samples of this installed on a corolla, Mazda 3, cavalier, and a subaru. All sounding pretty good in their own ways. The Mazda was a 2.3L 4cyl which I am confident is from the same engine family as the 2.5 duratec my van has. So I am optimistic on the outcome. I'll replace the resonator with straight piping, and attach the Borla to the end with a turndown. Now I just need the weather to drop back into the double digits before I start working outside. Quote Link to comment Share on other sites More sharing options...
stanger_missle Posted July 21, 2019 Share Posted July 21, 2019 This is something I have thought about as well. The stock exhaust is nearly silent. Some sound would be OK. I wonder how much the tone would change if you cut out the resonator (#1 on the diagram) and replaced with straight pipe? I'm looking for just a little bit of growl. Aftermarket mufflers are pretty much nonexistent in the stock configuration. On an unrelated note, after I bought my TC, I was curious if it was allowed to rallycross. That's when I found your post on Oppo. That looked like a ton of fun, even if it wasn't competitive. Did you have any problems bottoming out? I was looking for a skidplate (under engine cover?) and discovered that the 12-14 Focus uses the same plastic cover. There are quite a few aftermarket companies that make aluminum skid plates for the Focus ST. From my research, those should fit the TC. I haven't pulled the trigger yet but its on the list (along with about a million other things). Quote Link to comment Share on other sites More sharing options...
Fifty150 Posted July 22, 2019 Share Posted July 22, 2019 Get it custom made. Go to a metal shop. Give them the piece off the bottom of your van. Today, they could use AutoCAD to produce a piece in exact dimensions. I don'[t know if it will be worth the cost. But you'll have what you want. Quote Link to comment Share on other sites More sharing options...
jrm223 Posted July 22, 2019 Share Posted July 22, 2019 On 7/20/2019 at 4:41 PM, stanger_missle said: Are you trying to find an aftermarket muffler? The stock muffler is a goofy same side in-out design: The tailpipe is 2.25", but that inlet pipe looks more like 1.75" or so. A reducer/enlarger may be needed to make changes work right. Quote Link to comment Share on other sites More sharing options...
i86hotdogs Posted July 22, 2019 Author Share Posted July 22, 2019 16 hours ago, stanger_missle said: Did you have any problems bottoming out? I was looking for a skidplate (under engine cover?) and discovered that the 12-14 Focus uses the same plastic cover. No issues bottoming out. Most Rallycross courses are designed to avoid bumps, jumps, and other potentially dangerous features. A skid plate will never hurt, I've been talking to a guy who specializes in focus skid plates, and he agrees the similarity between the TC and the focus is almost identical. I loved racing the TC, and everyone got a kick out of it thinking it was a tow vehicle for another car. As for the exhaust, I am waiting for it to stop raining so I can get underneath and take off the pipe from the catalytic converter back and see how it sounds. If it's too much, I'll pick up the Borla Pro XS I mentioned earlier and put that on. Quote Link to comment Share on other sites More sharing options...
i86hotdogs Posted July 22, 2019 Author Share Posted July 22, 2019 2 hours ago, jrm223 said: The tailpipe is 2.25", but that inlet pipe looks more like 1.75" or so. A reducer/enlarger may be needed to make changes work right. Good eye there. I'll have to see for myself where I cut it what the actual diameter is. jrm223 1 Quote Link to comment Share on other sites More sharing options...
i86hotdogs Posted July 22, 2019 Author Share Posted July 22, 2019 12 hours ago, Fifty150 said: Get it custom made. Go to a metal shop. Give them the piece off the bottom of your van. Today, they could use AutoCAD to produce a piece in exact dimensions. I don'[t know if it will be worth the cost. But you'll have what you want. I don't see the cost benefits of a custom job for this vehicle. For starters, the only major bends or turns in the pipe is towards the rear near the left rear tire. other than that, it's a straight direction from the catalytic converter on. For something I can assemble with a few parts and a mig welder for $100, the shop would want no less than $300. ($300 is what they wanted for the wife's Chrysler 200 exhaust work: axleback muffler and piping) Quote Link to comment Share on other sites More sharing options...
Fifty150 Posted July 23, 2019 Share Posted July 23, 2019 You can buy pipes, elbows, and bends from Summit Racing. Then either use clamp on couplings or weld. Custom exhaust can be DIY. That is a really big muffler, which also appears to restrict the exhaust flow. Deleting the muffler will just sound bad. Maybe replacing the resonator with a glasspack unit may sound okay. I just don't think there's much to gain, performance wise, from exhaust work on this car. But it would still be fun to try something out. How about removing everything from the catalytic converter back? 2 bolts will disconnect the flange in front of the resonator. Then you could use a glass pack, and turn down. Maybe even use a Y-Pipe, route the exhaust out the sides, in front of the rear wheel. From the best of my recollection, MagnaFlow is a responsive company. Try contacting them. Maybe send that OEM exhaust diagram, and see if they have any recommendations. Quote Link to comment Share on other sites More sharing options...
davidparker Posted July 23, 2019 Share Posted July 23, 2019 @i86hotdogs Check out this post. There is a video of the sound of the 2.5 motor in a Focus with different exhausts. It might help you find the sound you want. https://fordtransitconnectforum.com/topic/6236-great-sounding-mufflers/?tab=comments#comment-20020 Quote Link to comment Share on other sites More sharing options...
i86hotdogs Posted July 24, 2019 Author Share Posted July 24, 2019 Got bored and cut the entire exhaust from after the catalytic converter on. The two bolts you see in the video wouldn’t cooperate. Sound is raw, but adds a lot of vibration in the cabin. I kept the exhaust, and plan on replacing the resonator with straight piping, and adding a Borla Pro XS muffler on the end of it. For the next few days, though, I’ll deal with the noise and vibration. It’s a Rallyvan anyways right?! Quote Link to comment Share on other sites More sharing options...
i86hotdogs Posted July 24, 2019 Author Share Posted July 24, 2019 @davidparker All I could find were the videos of the fusion with different arrangements. Regardless, that's a good reference. Quote Link to comment Share on other sites More sharing options...
Double Nickels Posted July 24, 2019 Share Posted July 24, 2019 1 hour ago, i86hotdogs said: plan on replacing the resonator with straight piping, and adding a Borla Pro XS muffler on the end That sounds like it will be good. Only concern is cabin noise without a resonator. You could always turn the radio up. Quote Link to comment Share on other sites More sharing options...
i86hotdogs Posted July 24, 2019 Author Share Posted July 24, 2019 2 hours ago, Double Nickels said: Only concern is cabin noise without a resonator. You could always turn the radio up. It being a cargo van, there's little to no insulation. Gonna need to add some dynamat or cheaper alternative to help that. Also, I'll still route it out the back of the van, so that will help with noise. Right now its directly underneath me and you can hear AND feel it. Quote Link to comment Share on other sites More sharing options...
Double Nickels Posted July 25, 2019 Share Posted July 25, 2019 Since you are rally racing, I would spray truck bed liner on the underbody. You don't need it to be pretty. It would help insulate, but more importantly, protect. Quote Link to comment Share on other sites More sharing options...
jrm223 Posted July 25, 2019 Share Posted July 25, 2019 On 7/24/2019 at 12:54 PM, i86hotdogs said: @davidparker All I could find were the videos of the fusion with different arrangements. Regardless, that's a good reference. Correct. It's the same 2.5L engine, although routing/placement logistics will be a bit different across platforms. i86hotdogs 1 Quote Link to comment Share on other sites More sharing options...
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