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2K views 8 replies 3 participants last post by  MyNameIdeasWereTaken 
#1 ·
Got a question for the fellow Volvo S40 2.4i owners.

Once I saw the difuser on the rear bumper of MyNameIdeasWereTaken I had to get it. I know that I can get the diffuser to fit onto my current one, but I don't wish to buy a whole new exhaust system. Is there anything that I can do to extend the exhaust pipe and make custom tips? or make my exhaust longer? Also sound wise, anything I can do?

Appreciate the help :)
 
#2 ·
Sound: You can de-unicorn the muffler by cutting off the closed tip (on the driver side) and pulling out all the fiber glass. That'll make things a little louder, you might also want to look into removing the resonator, but I'm not sure how that'll affect your pressure flow with an NA. http://forums.swedespeed.com/showth...er-what-the-inside-of-your-muffler-looks-like

Looks: You can have a shop cut off your down facing tip and weld on a straight tip, they can adjust the length to anything you want before welding it in place. After you de-unicorn your muffler, you can also have them weld on a 90° pipe and tip for a true muffler-back dual exhaust. You'll have to cut your lower trim (or buy a T5 trim) to fit the tips, but that's easy enough with a dremel tool and some sand paper.

My local shop will cut off the old tip and weld on a new one for $15 a side, so it's not expensive. The real money is in buying tips you like.

As for the diffuser I made, it was just the corners off a cutting board, you could do something similar for $8. ;)
 
#5 ·
Painted? What? If the metal is not finished or at risk or rusting, I understand, but otherwise I'm not sure why it would need to be painted. I don't know a whole lot about car "plumbing" so maybe I'm in the wrong.

Did you go with the Magnaflow cutout? I haven't had any issues with mine in almost a year, though we don't have salted roads down here.
 
#6 ·
#7 ·
Pre-facelift S40? #23 "with turbo" is the part you want. It'll be a direct fit.

The V50s have slightly longer bumpers, so make sure you get one for an S40.
 
#9 ·
Yeah, it should just be textured plastic. If it's not, Rustoleum Truck bed paint will perfectly match the texture of your current black trim.
 
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