The Exhaust System Upgrade: A Bolt-On Affair

We're about to upgrade our exhaust system on the RSE, and it's going to be a relatively straightforward process. The factory exhaust system is easily removable, and we can just bolt on the new one. But before we get started, let's talk about the different driving modes on the car. You know, which we can adjust using the various driving modes. But then you can also do some adjustment with some aftermarket things or you can delete it with a plug. We'll talk about those things afterwards.

The exhaust system upgrade should be a fairly bolt-on affair except for the use of an angle grinder mum. So, we can't just unbolt that one so the one that's on the car gets sharp. And then this one here gets bolted on and then once that's done man, we're ready for what you know what not? Yeah, okay? We've got an exhaust system now. We've got a front now. We got our intake. We've got a suspension. Let's turn it up wheels page up tires page up burn page up – I mean not burn, but well actually, we'll see. We'll see so today's the day to exhaust tower.

It's gonna be rad. Let's get to work on this exhaust system. It's gonna be an easy upgrade, especially when your mates are learning how to use a hoist. We need to make just one cut and then we can under the V-bends and remove the factory system. We've got our two exhaust side-by-side – the factory one on this side and our new one on this side now. There's a couple of small differences in the factory one. It is a European car, which often has metric measurements, but that's about 17 millimeters. That's a fairly uncommon size, only used for two-and-a-half-inch to three-inch pipes like that.

This one is 76 – that's 3 inches. You've got an extra resonator in here, which stops it from mooing and droning on the highway. But you've also got a smaller rear muffler, so the rear mufflers won't be quite as effective as the factory one, which is absolutely huge. What you also don't have on the upgraded one if you don't have these flat spots – the factory one has small flat spots that make it easy to get in and around things. They flatten it down.

Generally, if you're changing the size of the pipe, it's not great for performance. But the mandrel-bent exhaust we've chosen is pretty much the same deal. It's the same size the whole way through, which makes it easier to install. This is a really quick upgrade that can be done in around half an hour. But later down the track if we go for a bigger turbo, that's when we'll spend the time installing a suitable dump pipe to make sure we get maximum gains for our stage 2 focus.

Now, let's talk about swapping out the motor that runs the valve from the factory exhaust over onto the aftermarket exhaust. I'm doing this now – it looks like they've sourced exactly the same manufacturer. Which is good because it means we know that our fitment is going to be perfect. There's going to be a little spring inside this, and the spring is what keeps tension against the mechanism of the motor. The spring so when I pop this out – you'll see the little spring and that lines up with an indent on the inside of the valve.

Like that, so that little spring goes in there, and that's what operates, and I don't know if you can see down there but that's what's going to control oh. That little flap is so we're simply going to line up this spring again with that little valve, put this on – feel when that seats and hear a little click like that. Sorry for the 8 millimeters.

There are a couple of small differences in the factory exhaust system compared to our aftermarket one. One of them is that it has an extra resonator in here. The factory exhaust system also has a smaller rear muffler, which will affect its sound and performance. Our upgraded system does not have these flat spots like the factory system, so we'll need to adjust accordingly. However, the mandrel-bent exhaust ensures that our pipe is consistent throughout.

One of the main differences between the factory exhaust system and our aftermarket one is the spring tension. The factory system has a smaller spring in this spot, which makes it easier to get in and around things with flat spots on the muffler. To ensure proper fitment, we've taken steps to make sure everything lines up perfectly.

With our supporting mods done, next time on Mighty Car Mods, we'll load the RS up onto the dyno and bring on the boost.

"WEBVTTKind: captionsLanguage: enIn this episode of Mighty Car Mods were up to stage 5 of the Focus RSLet's call it stage 8We're at stage 8 of the Focus RS and we've got some very exciting mods to bump onto this mofo space a little bitWelcome to anotherFocus where you don't get dirty when you do work on it, this is done, I'm loving that is true our todayWe're doing a front mount. We're doing an exhaust. Yep. We got some other stuff over there. We got some other stuff over thereThere's little bits and pieces all over the place and they make stuff for cars didn't you?Sorry this you can get parts for cars it and you don't have to go to a wrecking yard you goHey look at this cool part. It's strange and then someone brings it to way back to the making yard very soonOh, I like both these things. I'm coming around to their work on the new car thing. Oh. Yeah, yeahIt's a nice experience. You don't get much who's following your faceYes, and it's like the this bolts aren't wrecked those five other people haven't been there before you that's trueThere's nothing I can say that's appropriate. That's a lead on to that but anyway, but what I will say is um todayWe've got the exhaust we got a front now, and then we're gonna boost itStage seven more boost no for its age eightSo more beige nine, maybe the lauric goes the better where it's stage eight, and then we'll boost upThat'll take us down to stage 5 and then our boost will land back on landing padsSo there it is now Martin over hereThis is it. This is see. This is one of these things. I told you about thatI bought a bunch of stuff from the unturned andOn this year, I didn't buy it they got a center. Yeah, they're like here's a thing so let's have a lookAlright, so let's see. We've got here. There are people everywhereWho are modifying their cars and their cars aren't old and crap well?Look at that they give you a cardboard thing if you want to paint a logo onNo, this is kind of big drawing it on thereThat's a big cooler, manhugeThat is big and black we should leave the cardboard on we should cuz it'll get damaged, otherwise, but how do I?We'll do a harmonic if I do this guyWhoa that's pretty cool. So um there it isIt's bigAnd it's black and as we all know black intercoolers make your car goFaster to upgrade the intercooler we need to remove a lot of stuff from the front of the Yaris including the lightsbumper undertray and brake ductsNotice you're not using the ventilation tubes no didn't need them todayBut I would like to know where the umLike where all the stuff that you pull off. Where do they go? Oh, you magnets doThat are they really gonna sell these in super cheap water yeah, they're not all that well. I've got submitted for approvalAnd seriously if they sold this I would IBuy a Yaris immediately just as a challenge if they're I would just buy it. That's and I would drive itThat would be my challenge to you if they actually sold it and agreed to it. I would just go okay then uhWhere are you gonna get all your new friends from friends exactly what?All right party time coming down whoa look at engineVery handy when they make them all the same it was good every single through. There is a science awesomeWith everything undone we can now start unclipping the edges of the bumperUnplug the lighting loom and then get the whole thing ready for removalSo everything's I'm done. We just have to pop it off. Now is that click done on the right sir yeah, that's undoneMoorings out on this side there. It is dad. Oh look. He's out stick upThat's awesomeSo as you guys might have seen we built this ourselves in Germany which was pretty coolAnd that was our little signature to make sure that umWell that it was authenticAnd there it isIt's gone on are over here mate mr.. Factory cooler, so this is the blanking plate they put on you can actually justLook you improved your intercooler efficiency. It's a blocking plate because I think in Europe where it gets really freakin coldI think there are actually two efficient. Well. They need to change up the thermal efficiency of it somehowYeah, I've been in AustraliaYou could probably just pull that off and you'd have an improvement the one we're putting in is much bigger though. YeahYeah, which for high boost applications and later on big turbo stuff like thatLittle plate there's off a transit noneFord Transit action onto the focus okay, well I mean the other thing is you've also got plastic in tanksWhich you know under mega boost is not going to be quite as as durableBut I mean factory cars have gotten so much better since the early days of intercooled stuff like it's come so far in30 years almostWhen was a Silvia 89 we're at 18 like it's close to 30 years?Let's put it in cool the other side of these brake ductsInside okay, I'll talk you this 25 top secondDown should come out somehow. Oh there we goYeah, it's coming out now if you pull itNice well still got a kind of map sensor disconnected something no not yet in one secondYou already got bugs up in the radiatorThat off so there it is that is theFactory Ford intercooler painted black of course for extra performance and stealth Martin the factory won't defend a black sir they didSo here's the new color couple of things to note firstlyIt's black man's black for extra performance and stealth we've got n tanksInstead of plastic ones probably the biggest differenceDimensionally is that it's a lot thicker it is isn't it?There's a couple of things to keep in mind in two colors, and one is that they flow differently internallyAnd two is that thickness we never liked the dimensions in every single way soWith - and thickness all makes a difference to how they performYou basically want the maximum amount of air to get through there to call the charge air which is inside it, but this shouldJust fit straight in place which is pretty cool actually Bolton well in this case. It's like a snapping snapping intercoolerYeah, it should just go straight in the front of the castle. It's in the boxThere was like another little bit of hardware in here somewhereAnd that make me believethatThere's just thesethey put the map sensor on theIntercooler that's different. I've never seen that beforeYeah, so I guess we've got to transplant that one there over to here. Oh, yeah, that's right. YeahCool, let's do itAll we have to do is transplant the map sensor from the factory into core onto the mountain intercoolerAnd then we've got to try and wrangle this monster into the same locationDid you grab if you grab right around the outside of it and sort of jam itI'm gonna plug this one first hung up like this the front holes pluggedSort of thick flange if it's just gotta go overI don't have just gotta tighten that thing around as tight as I can after a bit of an intercooler danceWe have got it in so we can attach it with the factory bolts and then connect the hosesMartin I'm just gonna put it out there that looks tough as all balls. It's really goodIt's big, but can you maneuver in there? It's pretty tricky because it's huge. Yeah, it looks madIt doesn't even know it looks you're hardly gonna. See it. Are you behind the bumper bar?Yeah, exactly, that's full stealth modebut you know what we did this video a few years ago called turbo supporting mods andDepending on what stage your car is that you might need a big front mount you might not sometimes the front nowIt's too big MartinYou got to do a smaller one and be but the point is is that this here gives you options that otherwise you?May not have and the factory in the core exactly is fine for doing what it was meant to doBut it isn't necessarily designed to do the stuff it wasn't meant to doPlease tell me gonna put a big turbo on it. Please do meMaybe you will mom maybe you should maybe you should bags not you do it. It's at the back of the engine bagCan you do it?All right, let's put the bumper back on man. All right go get ourselves someNibbles, I want GillyIf this bit that I'm doing right now. It was a movie. Do you know what it would be called?The bumper Point Break whyPoint great because it's blowing air on a break. YeahI'll just be in the wheel well if you need meDid you remember more making this and that girl was just laughing at us because it took us 45 minutesAnd she can do it in like 20 minutes. I mean her she's one person and we're two people I remember mr. SchmuckI think so Mike this is my new favorite German wordI'm pretty sure it just means smash it mateSmacking lucky who's cool? How does this go on alright? We've already done it we did it in GermanyWe should be able to do it here that bit goes up there this bit goes in here think theseIt'll slide in and these clips go under the radio to support which will kind of hold it onlike thatYeah, and thatWith the bumper reattached we can connect up the lighting loom and then put everything back togetherIt's crazy to think that just a little while agoWe were going through the exact same process with the same bumper, but we were in Germany in the factory assembling a brand new carWith everything reattached and double-checked our intercooler upgrade is done. That's so subtle man. YeahIt's just soYou can see it's like huge and fat and on the end tanks hereYou can see a bit of like a logo that maybe hinted at being something else butIt's just likeLook at that you just can't tell it's awesomeOne of the interesting things that the designer of this bar said is that like this?Bar and in fact a lot of the car is completely functional like every ventEverything on there rather than just being something that's meant to look coolActually has some purpose and it's kind of cool because a lot of cars doing stuffThat's not actually functional and that's all functional and that's pretty cool. Yeah, speaking of function check into motorbikes. Oh knowthatSo there it is the front mount is in it was a little bit of a trickier install then on a Japanese carBut that's probably because on a Japanese car you just get an angle grinder?Different way of thinking like all the plastics and all the kind of stuff and the bolts they use everything's talks like it's totallyDifferent but once you get your head in that space. It's the same as when you're working on golf for a yeahHow do you or something like that it's kind of similar in?Principle, there's a lot more parts here because if you think about like you got a silver you take the bad profitsJust like you just got this piece. This is like hundreds of pieces that make up the bumpI what I find interesting is that old mate who runs the plastic company who specializes in any cooler shroudsHe doesn't just go to the Audi Factory you guys down the road to the Ford factory and up the road to the Porsche factoryAnd goes I have this nice plastic and then they put it in the car, and it's of courseIt's the same and then they're like smacking Schmucker anywayThat was a very enjoyable time doing that mad install man, so now it is time toContinue the adventureHave a good flight awesome air all right. We are down here at Castle Hill exhaust and todayWe're putting an exhaust on the RSWhich is going to be?Exciting because we're going to look get a little bit more of that bubble snap crackle and pop the idea is to make a it'sA very quiet exhaust isn't it factoryit's a very quiet exhaust because it's got the factory flap around a black bar so we can open the flapper and put aNice meaty and big exhaust yeah, there's alsoI mean it is a big exhaust that Israel is a two and a half inch flip back to you oneYeah, yeah between two and threeIt does have some flatmates it kind of really pancakes down soWe have another exhaust to put on which we will show you all nowSo this is our exhaust that's going on the car as you can see this has been on a car beforeThis is the best exhaust you can get for a focus man, this is like the bestThis is the creme de la creme. Why why is it the best?It's the best because that's what we have MunAnd that's what we could get our hands on now even though it is secondhand. It hasn't seen a lot of lifeIt's got a little bit of a hit. They're a little bit dirty over here. There's some more of it over hereIt's a bit fat up more free-flowing. This is aMill Tech sport exhaust that is going on the car it also has that htlAdapter here where we're going to transplant the little motor from the factory under here, which gives us our little flat ability hereWhich we you can adjust using the different driving modes?But then you can also do some adjustment with some aftermarket things or you can delete it with a plugWe'll talk about those things afterwards soThis should be a fairly bolt on affair except for the use of an angle grinder mumSo we can't just unbolt that one so the one that's on the car gets sharpAnd then this one here gets bolted on and then once that's done manWe're ready for what you know what not yeah, okay? We've got an exhaust. We've got a front now. We got our intakeWe've got a suspension turn it up wheels page up tires page up burn page upI mean not burn, but well actually we'll see we'll see so today's the day exhaust towerIt's gonna be rad. Let's get to a night. This is a really easy upgrade on the RSEspecially when your mates are learning you their hoistWe need to make just one cut and then we can under the V bends and remove the factory systemWe've got our two exhaust side-by-side the factory one on this side and our new one on this side nowThere's a couple of small differences the factory one is actually pretty good for a stock car. We've got about 17, milIt is a European car which is often metric, but that's about two and three-quartersWhich is a fairly uncommon size and only two and a half three inch three and a half two inch stuff like thatThis one is 76 now that is three inches you've got an extra resonator in hereWhich stops it from mooing and droning on the highway?But you've also got a smaller rear muffler so the rear mufflers not gonna be quite as effective asThe factory one which is absolutely huge what you also don't have on the upgraded one if you don't have these flat spotsThe factory one you can see to get in and around things they flatten it downWhether that makes a huge difference or not some exhaust scientists will probably be able to tell usBut generally if you're changing the size of the pipe. It's not great for performanceYou've also got it where it squashes down as you go through a few bendsThis is a mandrel bent exhaust so it's the same size the whole way through otherwise. It's pretty much the same dealYou've also got the facility did put the motor on the same thing on this side so that you can turn it on and offAs the factory one does as well so it fits it's one of the easiest exhausts to install I've ever seen in my lifeThis is a really quick upgrade that can be done in around half an hourBut later down the track if we go for a bigger turboThat's when we'll spend the time installing a suitable dump pipe to make sure we get maximum gains for our stage 52 focusSo what I'm doing now is just swapping over the little motor that runs the valve from the factory exhaust over onto theAftermarket exhaust it looks like it's the exact same manufacturer if you look at this component hereAnd then you look at this component over hereIt looks like they've sourced exactly the same thing which is good because it means we know that our fitment is going to be perfectThere's going to be a little spring inside this and the spring is what keeps tensionagainst themechanism of the motor andThe spring so when I pop this outYou'll see the little spring and that lines up with an indent on the inside of the valveLike that so that little springGoes in that little valve there, and that's what operates, and I don't know if you can see down thereBut that's what's going to control ohThat little flap is so we're simply going to line up this spring again with that little valveput this onYou feel when that seats and hear a little click like thatSorry 8 mils and then this one here is are ready to go back on the carThis valve operates differently depending on which drive mode you're in so it can adjust the exhaust noise you can delete the valve completelyBut you need to buy a valve delete plug or the car will lock you out of some of the driving modesFor our stealthy objectives. It's actually a welcome addition in the pastWe've installedaftermarket systems on ourSubarus and missins that do a similar thing which keeps them under the radarSo getting a system like this from the factory is a real bonusTo make sure the exhaust tips are sitting in the perfect position we're using the Sherrill techniqueAnd that's it how exhaust is done?With our supporting mods done next time on Mighty Car Mods. We load the RS up onto the dyno and bring on the boost\n"