Early 996 exhaust replacement

[Cayenneand996]

Any thoughts on replacing the rear exhaust boxes on my 1998 996 cab. The original factory silencer boxes are just starting to blow due to rusting where the pipes meet the box so its time to look at replacements. Its not too bad yet, but no doubt the next MOT will pick this up. The car has just covered 50k miles

I have seen pairs of boxes on ebay for £450 upwards or stainless for £700. I am guessing I will need a fitting kit as all the clamps will be rusted?

I don't want to spend too much money but happy to consider sensible options so I am looking to see what others have done and understand my options.

Is this a home replacement job or better done by a specialist or a good Independent? On any other car I would always fit exhaust parts myself, but it looks complicated under there after taking a quick look under the car.

Your thoughts are appreciated

[Cpt Stirling]

I think it depends on what you want. I have Dansk replacements and increased noise over OEM. Just an observation and from what I've read the flexipipe is a weak point. Topgear in Bridport offer a choice and quality seems good at a reasonable price. They offer fitting too and good customer service. It's where I will go next. I wouldn't do it myself and I'm not completely useless with a spanner. Some fettling may be needed especially with non OEM. Use quality clamps, nuts and bolts. If you decide to consider Topgear give them a ring, you may get a discount on the eBay price.

[Fastlane]

There are several options available - Dansk, DesignTek (the previous owner fitted SuperSounds to mine) and TopGear to name a few. I believe removing the silencers is relatively easy - it's the manifolds that most people leave to a specialist because of rusty bolts.

I would suggest you hop over to 911uk.com and do a search on the 996 forum - there's lots of info, on there. For example, Dansk seem to be suffering from quality issues vs TopGear who seem to be building a good reputation (I have TopGear manifolds on mine, fitted by the previous owner and they seem good). See this thread re Dansk vs TopGear silencers http://911uk.com/viewtopic.php?t=120362

[Chris Stott]

I've just had Dansk backboxes on my 996.

The standard Dansk backboxes have a lovely sound at c.3k, but nothing at the top of the rev range... I did the Helmholtz hack to add a bit of induction noise, but if I was going again I'd choose different backboxes.

[EGTE]

Dansk quality and commitment to honouring warranty is poor:

http://www.911uk.com/viewtopic.php?t=120362


TopGear exhausts were so appalled, they stepped in and gave a set of back-boxes to the guy.

Needless to say, I know which company I'll be going to in the future.

[IknowJoseph]

I had the Dansk Sport Stainless backboxes fitted to my car: They spat out all their wadding and became incredibly loud. Replaced under warranty.

I would most likely try something different next time. Perhaps stick with the OEM boxes and get a different sound by changing the manifolds.

[Polome]

I changed the exhaust boxes on my 996 when it was about 10 years old. Manageable on driveway ...best to raise car in air...remove bumper...remove heat sheilds. I ended up grinding and hawksawing fittings and clamps off as were too far gone to attemp spannering. Unless your cars been done previously the clamps/ fittings are sure to be a corroded mess. Remember to use plenty copaslip on joints and threads when refitting , you'll appreciate it if you want to remove the boxes again... also when your sure all is correct a good idea is to cut off the protruding redundant bolt ends as they are doing nothing and when they corrode again your back to square one! If only the factory used assembly paste it would save a lot of dismantling heartache ....good luck.

[monty999]

Dansk stainless sport boxes on Eurocarparts at £550, fitting kit with all the clamps etc £26. Easy job as described before. I didn't remove wheels, just drove rear wheels onto some wood 4'' high planks. The three mounting bracket nuts/studs may shear but is easily replaced by new nut and bolt, (just one of mine sheared). Happy with the sound, not too loud but a bit more throaty than stock. Plenty of info on youtube for removal of bumper cover and heat shields if you're not sure of fixing points.