In the scale of 1-10, I think that the Boxster’s exhaust stock sound is a solid 4.5.

It always bothered me that my car sounded so mellow and lame.

I had test-driven a few Boxsters with aftermarket exhaust systems but all of them had an annoying droning or resonance at different engine speeds.

The one exhaust I liked because it did not resonate, but was not loud enough for my taste, was the Porsche Sport Exhaust (PSE).

So, one day I decided to make my own version: The Pedro Sport Exhaust (PSE).

I decided to modify my own OEM muffler by using modified guidelines of the Porsche Sport Exhaust.

It needed to give me the sound I wanted without the resonance inherent to the aftermarket systems.

After about 5 hours of work, I got it!

Listen here at a sound clip of my car right after I made the Pedro Sport Exhaust.

This is a 0 -125 mph run.

Sorry for the wind buffeting.

In order to be ready for the PSE assembly, I had first gone to a home improvement center and purchased a section of flexible copper tubing in 1/2 inch diameter.

I hand bent this flexible tube into the desired shape right on my muffler.  I wanted to get the exact curvature and length.  Once I had the desired curve I cut it to size and took it to a mandrel-bending shop which I found in the Yellow Pages.

I asked them to replicate the bend on a 1.25” diameter stainless steel tube which they also provided.

If I were to do it again, I would use 1.5” diameter tube instead.

I also left the long end of the tubes a little longer than needed.

If you don’t have access to a lift you can use a pair of strong ramps to raise the back end of the car and be able to comfortably remove the muffler.

Once the muffler is out you can start to measure and cut.  You’ll need a good grinding unit and bits.

I used a hand drill with different size bits and a Dremel.

Carefully mark the center line of the Oval or Tube exhaust and draw the outline of the tube.

Start drilling and grinding until the end of the tube fits snugly.

Now, mark and cut the hole on the muffler’s entry tube.  Keep in mind that this hole will be oval shaped because of the angle of the bend in the stainless tube.  With the tube in hand, keep grinding and measuring until the tube fits snugly.  Then you can present the tube in place prior to welding.

I tried to get the tube to be parallel to the seam of the muffler.

Weld (in my case braze) the first tube in place by welding both ends to the muffler. It’s important to get the weld at the intake of the muffler airtight.  The other end (tip) is not that critical.

With one side welded in place, drill out the holes on the other side of the muffler.  Try to be as exact as possible, because the tubes need to be at the same height and at the same angle vs each other and they are visible from behind.

If you get the drilling on the tip side correct, then you can adjust the length and or angle of the tube somewhat by rotating, shortening or lengthening the position on the muffler’s other intake side.

Insert the tip side first and then take measurements from the tube to the muffler’s seam and compare

with the already welded side.  When you’re ready tack in place.

You don’t have to weld on the inside of the tip(s).        I had previously installed a set of headers.

Now it’s just a matter of putting it all back together in the car.

Make sure you tighten all the loose hardware, such as clamps, bolts and nuts.

Go enjoy!

Happy Boxstering,

Pedro