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Old 09-30-2014, 10:50 PM   #1
qwkswede
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Default Lets see some 240 performance exhaust ideas.

Hey turbobrickstas. I need some exhaust ideas for my 240. The rear muffler just rusted and fell off my daily driver 240. The car will be turbocharged soon with a moderate boost 200+ hp build for daily driving. And now I need to figure out what to do with the cat back pipes and mufflers in a hurry. I figure a stock NA 240 exhaust is not going to help me with future plans. I'm a bit new, or more honestly forgotten everything I learned 25 years ago when I used to own modified 240s. I haven't really thought about this much until today when the muffler rusted off. Where do most people route the exhaust around the axle on a 240? Is there room over the top? I'm thinking 3" or 2.5" pipe, all the way out the back with a single muffler in the stock location. What works best with lowered cars? Is anyone selling a nice kit that bolts on to save me some time in a pinch?
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Old 09-30-2014, 11:11 PM   #2
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3", 14x8x4" or similar sized straight through muffler in the resonator location, under axle, straight out the back. Or if you want some noise, fit a hotdog/bullet in place of the muffler.
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Old 09-30-2014, 11:19 PM   #3
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I still have a 3" over the axle system (not compatible with crash triangles) from SAM, from a group buy many years ago. I was going for stealth, it has two straight through mufflers (you can see 3" with no obstructions through both). It's not quite as quiet as stock, but it's not loud either. Just what I wanted.
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Old 09-30-2014, 11:22 PM   #4
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Quote:
Originally Posted by Dauntless View Post
...under axle.
Under axle shows lack of talent. Over axle keeps everything serviceable, and 3" isn't at all necessary if the power goal is only 200hp. I personally like quiet exhaust systems, so I'd go 3" DP, then a 2.5" cat -back, a Dynomax bullet in the resonator position and a 12256 Magnaflow in the rear muffler position. Would have some tone, but not annoying.
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Old 09-30-2014, 11:35 PM   #5
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Interesting. So you can go either way around the axle even with 3". The SAM system I ran on my 740 was nice. Have any pictures of it from underneath? I'm not sure I have the bandwidth to tackle a project like that in the next week. But I'd like to see it. If I can copy the basics in 2.5" I might have something reasonably quiet.
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Old 09-30-2014, 11:44 PM   #6
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I'm sure I can make all the power I'll want in a DD car with 2.5"

Anyone running really low with an over the axle exhaust? Like short struts up front and zero bump stops on the rear axle?
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Old 09-30-2014, 11:47 PM   #7
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I have an ipd/tme exhaust in mine. Mandrel bent, 2.5", over axle. It's way nice, but also incompatible with crash triangles. RSI has put together several over axle systems with resonators up front and no rear mufflers, exiting on the passenger side. They look very slick. Perhaps you could get them to put together a quickie kit for you.

Quote:
Originally Posted by qwkswede View Post
I'm sure I can make all the power I'll want in a DD car with 2.5"

Anyone running really low with an over the axle exhaust? Like short struts up front and zero bump stops on the rear axle?


That picture below be a 16" wheel almost tucking.
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Old 09-30-2014, 11:52 PM   #8
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Another one:



Zero issues with axle to exhaust contact.
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Old 09-30-2014, 11:55 PM   #9
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Quote:
Originally Posted by qwkswede View Post
I'm sure I can make all the power I'll want in a DD car with 2.5"

Anyone running really low with an over the axle exhaust? Like short struts up front and zero bump stops on the rear axle?
Look at my 244 exhaust in my build thread, I've got easily 4-5 inches of axle clearance before anything will hit with a 3" over axle. Tight now the rear has cut diesel springs (3 coils removed). I've got some Jeep grand Cherokee springs I will cut down and install in the future, but I needed to keep the car high enough to tow around in the meanwhile. With 2.5" you'll have a mile of room up there.
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Old 10-01-2014, 02:55 AM   #10
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Cool. Thanks for the tips guys. I'll drive my other car for a few days and get some tubing and mufflers ordered up. While I appreciate RSI's efforts for the Volvo community, I don't think I would ever call them for something I need shipped immediately. I've been down that road too many times and burned. I can get some U bends and tubing here pretty quickly from other sources.

I need to get the car up in the air and get a look at the bushings and some other things too. I'll just spend the next week getting some stuff improved.
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Old 10-01-2014, 08:51 AM   #11
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Mine isn't that low. It's on IPD lowering springs. But there is plenty of clearance around the over-the-axle piping.

I don't have any pics of it, but I could probably take some if needed.

Crash triangles and corresponding caliper ears are removed on both sides because..... racecar.
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Old 10-01-2014, 09:06 AM   #12
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This is the RSI built 3" that I have. I was/am really impressed with it, best fitting exhaust I've ever bought and really beautifully made. No cat, one single magnaflow in the back that is really small. As with most turbo cars it still is not really what I would call loud. You can tell there's something going on, but it's not loud.

It's under axle, which I have no problem with. My car is plenty low and the axle portion is well clear of being the lowest point on the car. I'd have to be going over a pretty wide speed bump to have any problems back there. My YoshiFab lower chassis braces are easily the sore thumbs of the bottom of the car. The bend in the pipe after the downpipe is the low point of the exhaust, but I haven't had any issues and don't expect to if I use my head. I live in frost heave, expansion crack whooped out New England so if I can do under axle anyone can. As far as "serviceability" with under axle, I can have the back section of the exhaust off in literally 5 minutes (v-bands for the win).





and a crappy video of what it sounds like
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Old 10-01-2014, 09:37 AM   #13
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I haven't done an over the axle exhaust yet on a 240 but the next one i do will be that way. Under axle is cheesy and easy.
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Old 10-01-2014, 02:21 PM   #14
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Im running a full 3.5in over the axle with 2 spiral flow "mufflers", one where the cat would be and one in the rear. The tone is perfect, low and mean. With only one spiral flow muffler its little louder and angrier.
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Old 10-01-2014, 02:41 PM   #15
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any side exit options? Saves the 'over or under' decision....
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Old 10-01-2014, 02:53 PM   #16
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any side exit options? Saves the 'over or under' decision....
now THAT'S cheesy
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Old 10-01-2014, 03:10 PM   #17
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Yeah, that option scores low in the comfort scale.
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Old 10-01-2014, 05:36 PM   #18
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Yeah, that option scores low in the comfort scale.
unless your already deaf in the R ear.
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Old 10-01-2014, 05:37 PM   #19
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unless your already deaf in the R ear.
Or are unable to feel the resonant vibrations or smell exhaust fumes.
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Old 10-01-2014, 05:39 PM   #20
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all of the above
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Old 10-01-2014, 06:13 PM   #21
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Originally Posted by icwbmx View Post
Im running a full 3.5in over the axle with 2 spiral flow "mufflers", one where the cat would be and one in the rear. The tone is perfect, low and mean. With only one spiral flow muffler its little louder and angrier.
Do post a picture, I wanna see it as I'm sure everybody else does too. 3.5" seems pretty overkill unless the car is making 800+ WHP. 3.5" has gotta be tight, I wanna see!
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Old 10-01-2014, 06:36 PM   #22
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My catless, skinny muffler side exit required ear plugs to drive the car for more then 10 minutes. it was LOUDDDDDDD

It exited right next to the rear passenger side jack point

It's light and simple but not practical

Last edited by blkaplan; 10-01-2014 at 07:06 PM..
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Old 10-01-2014, 06:51 PM   #23
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For those of you running cats after the downpipe, what are you using and where are you mounting them? Also, where are you putting bungholes (tee-hee!) for wideband?
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Old 10-01-2014, 07:00 PM   #24
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Simple side exit right after the tire.



Quote:
Originally Posted by blitzkrieg59 View Post
For those of you running cats after the downpipe, what are you using and where are you mounting them? Also, where are you putting bungholes (tee-hee!) for wideband?
you can see the cat near the trans.
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Old 10-01-2014, 07:30 PM   #25
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Quote:
Originally Posted by stevE85 View Post
Under axle shows lack of talent. Over axle keeps everything serviceable, and 3" isn't at all necessary if the power goal is only 200hp. I personally like quiet exhaust systems, so I'd go 3" DP, then a 2.5" cat -back, a Dynomax bullet in the resonator position and a 12256 Magnaflow in the rear muffler position. Would have some tone, but not annoying.
My 240's original exhaust was under axle. I don't see how it shows lack of talent, it uses less bends than over axle, especially on a lowered car. It also makes the exhaust much easier to remove. The only job it would be in the way of is replacing the diff.

Here are some pics of an exhaust made by a shop with no talent. Zero issues after 8 years and 70,000 miles. Based on the shape of the swaybars, Volvo clearly didn't intend an exhaust to be routed under the axle.



Last edited by Dauntless; 10-01-2014 at 10:31 PM..
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