321freeflow

Nah - there's a very bad man on there calling him names.

Many thanks for your input guys, much appreciated. Cheers.

Yup - 20bhp is prolly an unrealistic expectation(he says, sweating)! The manifold is a 4-2-1 design but with the collectors are "stacked" ie no secondary pipes at all - works for me!

Yes, I know the Caterham site states 230bhp for the R500 but is that "real world" - at the wheels? Sorry, should have made it clearer, my system runs straight to the rear valance on the Elise/Exige cutting out all the 180 bends etc.

This week, I'm going to be dyno-ing a new design exhaust for the K-engined Elise/Exige. The engine builder tells me a "guru" informed him that Caterhams, because of their short run of exhaust regularly show 20bhp more than the Elise/Exige!! Now, I'm willing(reluctantly), to believe that a Caterham exhaust versus a STD Elise/Exige exhaust MIGHT show SOMEWHERE on the curve a 20bhp gain - ie a spike on the Caterham curve coincides with a dip in the Lotus curve - but never a 20bhp on the peak reading!! My question is - how many 230bhp K-engined Caterhams are out there? (I say 230bhp because the Exige I'm using is showing 210bhp at the mo).

Absolutely no idea! If you can only remove one end-cap then try this: Fab up a cardboard tube that will slip over the perf core tube, then wrap the stainless wire wool (loosely) around the cardboard, follow this with a good few layers of cling film. Slide the cardboard tube down over the perf and using a twisting, screwing action ease it out leaving the wire wool wrapped around the core. If you can reach, use masking tape or equivalent to tape the end of the cling film/wire wool wrap to the perf. Now, use 'E' glass fibre (long strand - it'll stay in longer, aided of course by the stainless wire wool) to pack the can. It's difficult to quantify but pack it tight without ramming it 😳 The cling film and masking tape will burn off when you fire up so don't worry about the smoke.

Guinea pig car? Would like a definitive noise test done on a Caterham with my new silencer, yes. Don't have to prove the design works - it does! Will be at Ricky Gaulds tomorrow, so mobile signal is p*sh but yeh, please call me any time Monday. Cheers.

Don't use Basalt fibre, it's crap. Burns away far too easily. Wrap the perforated core tube in Stainless wire wool (loosely). Then wrap again with cling film, this keeps the wire wool in place and makes the next task a whole lot easier. Pack the silencer with 'E' glass fibre. If you can't remove the core tube to do the above, then your silencer is badly designed.