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RS Barn's "Stage 2" Exhaust/Chip system
#1

I have installed the RS Barn Stage 2 exhaust/chip modification in four stages over the past several weeks, and am writing to report on my experiences.

I had previously installed a Speed 6 chip, and later cut in the famous airbox modification: the Speed 6 chip was eventually removed to make way for RS Barn's 'custom'-tuned replacement.

I first installed the catback system, which produced a nice beefy exhaust tone and placed a larger tip on the exhaust to replace my OEM chrome (SS?) rolled tip, but had a small effect on power at best. After a few weeks I called Pete up and he offered attractive discounts to add the header/cat/chip as a package, which I ordered.

It has been mentioned here that the RS catback puts the muffler in at an 'angle'. I took that to mean that the muffler was skewed horizontally, but it turns out the muffler is tilted counterclockwise along the axis of the pipes. A photo below illustrates this.

It took a while for the header/cat package to to ship. Pete sent out the chip in advance, and I installed it in place of my Speed 6 chip. I noticed little change except a strong tendency for the car to lag noticeably when flooring it in the 2K rev range in 2nd or third: the kind of driving you might do in traffic when trying to scoot out of someone's way or pull out quickly from a rolling stop. However, the chip is programmed for the presence of a full exhaust retrofit, so I waited to see what would happen when everything was in place.

Within a month of having installed the catback I had the full Stage 2 system installed. It's a real and total pleasure to drive, representing at least as dramatic a difference in performance as the (ahem, somewhat less pricey <img src="/forum/images/smilies/968/wink.gif" class="smilie" alt="" /> ) airbox mod. Combine chip/airbox/exhaust to make up the Stage Two system and you have a major performance boost which reveals itself in generally more relaxed and exciting city driving as the torque curve smoothes out, overall much better power and tractability, at least in a seat-of-the-pants way. (I plan to dyno the car soon, but I have no pre-modification baseline to compare to.)

There are two issues worth noting. The first is that adding the header to the catback install made a big difference in the tone and loudness of the exhaust, and not in a good way. I had asked about this as I considered the header upgrade: would the car get louder? Pete replied that the difference in sound with the header/cat change was minor. This turned out not to be the case: the car took on a 'bratty' pulse which I found irritating from the minute the header/cat went in. There was also a slight rattly resonance which occurred under load and at speed: press on the accelerator at highway speed and the exhaust sings a bit as the engine picks up. This I could live with easily, but the 'brat' thing had to go: it was irritating, and made me feel like I was driving a goosed-up WRX around the neighborhood.

On the phone Pete acknowledged that as more systems went into the field this was being reported back: he says that cab owners note it more, but I think this may have been a function of the season: if you have your coupe's window open you can't avoid noting the intrusive sound your car is now making. He told me that a resonator had been developed for just this reason: it goes behind the cat and is said to have minimal effect on power. He sold me one for $90.00 with the old pipe to be returned to RS Barn.

Today that went in- my shop was kind enough to do the swap gratis. The car sounds much better now: just where I want it. The car is probably a bit quieter than it was when the catback system went in by itself, and that's fine with me: there's still a nice strong note there, but no buzz. I honestly forgot to listen for the power-on resonance I mentioned above, but the fact that I didn't notice it on the way home probably means that sound has been tamed as well.

I don't trust my judgment enough to state with any certainty what's happened to power with the resonator added. I sense a tiny diminution in power with the resonator installed, but if anything's happening it's very minor. I would recommend the resonator to anyone with even the slightest hint of a concern about noise: of course you could presumably install Stage 2 without, and then retrofit the resonator should you desire, but in my case that swap involved a little under $40.00 of extra shipping charges alone.

The sag-when-flooring-it issue remains however. Pete and I will be discussing this in the next few days and I'll probably have more to report. (ON EDIT: I think it's important to note in this first post of the thread that this problem was resolved easily with Pete's friendly assistance: the intake system was cleaned out and the problem is gone.)

In short: do it! The car is so much more fast, responsive and fun to drive with the exhaust system and custom chip in place. If you can afford to, put it in!!!

<img src="/forum/images/smilies/968/biggrin.gif" class="smilie" alt="" /> <img src="/forum/images/smilies/968/biggrin.gif" class="smilie" alt="" /> <img src="/forum/images/smilies/968/biggrin.gif" class="smilie" alt="" />



Pictures:

Here's the back of the car, which needs washing. You can see the angled muffler, and also a faint bloom of soot: this freer-flowing system deposits more stuff on the back of my car. That the tailpipe seems off-center is an illusion caused by the angle of the photo.

   



It's hard to capture this in a photo, but it's really neat the way the four header pipes complement and complete the appearance of the four intake manifold runners.

   
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#2

P.S.

Does anyone think that the dirty exhaust and lag when floored combine to indicate that the car might be running rich? If so: how would one address this?
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#3

Everything else aside, I must say - that's one good looking engine. I dont't think there's no way I could get, much less keep, mine looking that way.
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#4

That would be my first thought... If you have all the prescribed parts for the Stage II and RS did their homework, the A/F mix should be correct or close. It all depends on how the fuel map is set up, [it may be too fat at low rpm?].

Another check would be to take a run at highway speed and then check the color of your s/plugs. If they're black too - the a/f mix is a we bit too rich...
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#5

the exhaust is a great performance mod.

i have also had more carbon coming out of the tail pipe since the install.

i do not, however, have pete's chip yet.



i think you could twist your muffler so that it sits parallel to the ground. mine looked like your's originally and i had to sort of jerk things around to make them proper before tightening up all the clamps. i could post a pic if you'd like.



i didn't realize that he had a resonator. i think it's a great idea. i'll agree that it's worth the noise, but it'd be nice to have it a tad quieter. when driving through neighborhoods, it's nice to not wake everyone up.
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#6

When I had mine on the dyno after the stage 1 stuff I think my a/f was 12.5 +/- 0.2 from 2500 up. It was a crappy pull and crappy dyno place that had never seen a Porsche before so I didn't get a second pull in. I'll have to check it out tonight an see if there is a problem around 2000 but I don't remember feeling one before. I also have been lazy and haven't washed or looked a the back of the car for a few weeks so I'll have to check the soot residue. I do think the tip angles up more so it very well could be getting more on the bumper than before.
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#7

My muffler definately does not sit swisted like that. It follows the lines of the car very similar to how the OEM did. The only 'angle' that I have is the muffler sloping up to the rear bumper cover. Both are fairly obviuos in the attached photo. As stated previously, there is a lot of wiggle room with the muffler and tip.



   
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#8

My header and stage II chip came today <img src="/forum/images/smilies/968/biggrin.gif" class="smilie" alt="" /> As soon as the DD comes off the lift this weekend, I'll toss up the trackcar and get it mounted. I plan to take it to the dyno afterwards to make sure all is well, I'll post results.
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#9

[quote name='bibbetson' date='Apr 27 2006, 10:44 AM']As stated previously, there is a lot of wiggle room with the muffler and tip.[/quote]I'm not a mechanic but on examination I see that the whole muffler's over to the far left of the area it's intended to occupy, with its left rear corner (the low side) less than 2" from unshielded body sheetmetal. That would seem to indicate that the system ahead of the muffler needs to come down, and I'd rather have the clearance. This tilt is really apparent in the photo I posted above, but I hired a neighbor's daschund to take it. <img src="/forum/images/smilies/968/tongue.gif" class="smilie" alt="" />
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#10

[quote name='Lemming' date='Apr 27 2006, 10:59 PM']My header and stage II chip came today <img src="/forum/images/smilies/968/biggrin.gif" class="smilie" alt="" />  As soon as the DD comes off the lift this weekend, I'll toss up the trackcar and get it mounted.  I plan to take it to the dyno afterwards to make sure all is well, I'll post results.[/quote]Great!

I'm hoping others who have installed this upgrade will report in here: on a personal level I'm particularly interested in whether others are experiencing the throttle-sag (or whatever you'd call it) I mentioned in my report.



Pete says it's new to him, and suggested new rotor/cap/wires/plugs and an induction cleaning

(Run-Rite) of the intake system. Most of those components happen to be new on my car: I ordered NGK iridiums day before yesterday and will throw them in when they arrive. Looking around for a shop and pricing for the induction cleaning.



Please- other users of this upgrade: any impressions you'd care to share here?
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#11

no sagging here.

if anything, i think the exhaust helped eliminate the sag that was in the car before.

originally, it almost felt like a turbo with the variocam kicking in (i can't remember, was it around 4k rpm?)

with the exhaust, my experience has been that the accel has been much more steady and streamlined. it feels to me that the accel kicks in much more quickly. still pulls harder at 4k rpm, but it isn't boring getting to that point anymore.



now, i don't have his chip yet, so i can't comment on how that affects things. i have an old autothority chip from like 10 years ago. i plan on ordering pete's chip, but am waiting on his further enhancements so i don't have to change chips twice.



hope that helps.
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#12

Thanks. Again, my issue is clearly related to the chip. The problem started when the chip went in, before the header/cat setup was installed.
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#13

pete's programming is very mixture focused, whereas the racer x is mostly timing focused - if you put the stage 2 chip in there, without the stage 2 parts, you are probably running rich - when you floor it at 2k, you dimp fuel in there, and it has to catch up



i had similar experiences when going through this - it is very important to have the right chip for the right setup - this is one of the reasons pete's software outperforms the others, whichever version you have, but you need the right one for the setup on your car



it's amazing how sensitive these cars are to mixture
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94 Midnight Metallic Blue Cab Porsche 968 w/deviating cashmere/black interior and WAY too many mods to list - thanks to eric for creating www.968forums.com



"It isn't nearly as expensive to do it right as it is to do it wrong."
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#14

He has all of the Stage 2 stuff installed with the Stage 2 chip, he just did it in stages, no pun intended. I wonder if resetiing the ECU, sorry brain lock and using Honda terms but can't think of the proper Porsche terminology, would do it.
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#15

Thanks, Mark.

Yes: Flash, if you read the initial post here you'll see that-



• First the catback went in.

• Then the Stage Two chip replaced a RacerX *and the 'sag' problem showed up.

• Then the header/cat combination went it: problem remained although probably reduced.

• Then the resonator went in: no real change, I think.





*It was going to take a while to get the header here and I had work planned for the ECU area anyways. Pete thought it would work fine without the header so he shipped his chip in advance.
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#16

it resets after the chip being out for 30 seconds - that shouldn't be the problem



i had exactly the same sag too - it was really falling on its face down there - turned out i had 2 issues - the first one was a bad connection at the hall sensor - no lights tripped - a blink test showed it though - what was happening here was the racer x, which achieves most of its power through timing, was masking the faulty hall sensor



here in los angeles, we seem to have air that is more dense - i had forgotten that a lot of guys adjust mixture for here - at pete's suggestion, i increased fuel pressure 4psi



all seems to be right now - i still think i remember the car launching a bit better, but that may well be to the change in location of mass at the wheels - while i have nearly the same overall, as before, i now have more at the outside, and less at the hub - this would adversely affect low rpm launch



it seems that the farther we go in mods, the more sensitive things become - i'd do a blink test, to rule out the problem i had, and then look at the injectors
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94 Midnight Metallic Blue Cab Porsche 968 w/deviating cashmere/black interior and WAY too many mods to list - thanks to eric for creating www.968forums.com



"It isn't nearly as expensive to do it right as it is to do it wrong."
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#17

I have done a blink test and nothing shows. Forgot to mention that in the initial post. Thanks for chiming in here, though: it's appreciated. <img src="/forum/images/smilies/968/smile.gif" class="smilie" alt="" />
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#18

I wonder if the increased fuel pressure is needed partly due to less humidity in SoCal.



[quote name='flash' date='Apr 28 2006, 09:40 AM']it resets after the chip being out for 30 seconds - that shouldn't be the problem



i had exactly the same sag too - it was really falling on its face down there - turned out i had 2 issues - the first one was a bad connection at the hall sensor - no lights tripped - a blink test showed it though - what was happening here was the racer x, which achieves most of its power through timing, was masking the faulty hall sensor



here in los angeles, we seem to have air that is more dense - i had forgotten that a lot of guys adjust mixture for here - at pete's suggestion, i increased fuel pressure 4psi



all seems to be right now - i still think i remember the car launching a bit better, but that may well be to the change in location of mass at the wheels - while i have nearly the same overall, as before, i now have more at the outside, and less at the hub - this would adversely affect low rpm launch



it seems that the farther we go in mods, the more sensitive things become - i'd do a blink test, to rule out the problem i had, and then look at the injectors

[right][post="19998"]<{POST_SNAPBACK}>[/post][/right][/quote]
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#19

nuts - i'm about out of ideas - it's probably fuel related though, so i'd poke around and check the things connected to the system that might be mucking the mixture up



i plan to change out my O2 sensor, plugs and wires and such this week too - it's time, and they don't last as long when pushing the car the way i do



also sending out my injectors - turns out, in setting the fuel pressure, that i discovered at least one that is a bit leaky - it wouldn't hold static "switch off" pressure up to spec



trying to make sure that everything is up to snuff - then i can really get a feel for where it is



but it really seems to be incredibly fuel sensitive now - a pound of pressure is a noticable change



definitely faster though
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94 Midnight Metallic Blue Cab Porsche 968 w/deviating cashmere/black interior and WAY too many mods to list - thanks to eric for creating www.968forums.com



"It isn't nearly as expensive to do it right as it is to do it wrong."
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#20

flash- do you have the gauge to measure fuel pressure? last i heard, the parts were no longer available from our old friend. i've held off on replacing the regulator because i couldn't find the gauge anywhere.

also curious if you now have the press at stock level or do you have it customized for the exhaust?

i'm due for a fuel inj clean and thought that it might make sense to add the adj fuel press reg at this time. any thoughts? thanks.
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