240: IPD Sport exhaust...

[volvoboy90]

Hello all! Well my shortened exhaust on my 89 failed me yesterday with the end of the catalytic loping off, and sounding like a lawnmower... So I am looking at replacing the whole thing since I know there will be no separating the catalytic pipe from the resonator... For 30 dollars more, I am looking at IPD's sport exhaust... Reviews look good, but I am wondering if anyone may have some better ideas... my budget is extremely confined, I am nearly fainting from looking at $335 to replace the cat and back.

[TrickMick]

within the last month I sent the "DIY SPORT EXHAUST" stuff to a
fellow TBrix fettler....can't remember if it was a PM or an "off list"....
if he sees this maybe he can "copy to this thread"??

I had all of the "genuine part numbers" listed as well as all links tested....
hmmmm....

[Redwood Chair]

Go to the JY and jank a 60mm one off of a 240T for $35.00.
It's what we do in Cali.

[volvoboy90]

Just looking for the best bang for my 350 dollars, lol. Getting a magnaflow cat for less than a hundred and Ipd wants 235 for the sport exhaust after ship.

[volvoboy90]

And unfortunately no jy's close to me here in the rust belt.

[Redwood Chair]

Originally Posted by volvoboy90

Just looking for the best bang for my 350 dollars, lol. Getting a magnaflow cat for less than a hundred and Ipd wants 235 for the sport exhaust after ship.

Somebody had a new one in for sale the other day.
Did you even search bro?

[volvoboy90]

I searched... It sold.

[Redwood Chair]

[volvoboy90]

I searched Ipd sport exhaust and it popped up... A few days late, I'm afraid.

[beigebricker]

I got a good setup from fcp groton. Its a 240 turbo muffler, under axle pipe, intermediate pipe and a 1980 240 non turbo header pipe (has longer secondarys). All u need to do is get a 2.25" to 2" pipe adaptor from autozone and weld the header pipe to the intermediate pipe. This setup is better than ipd, bc that id what i had on there before, and its cheaper.

[volvoboy90]

Hmm..... I'll look into that. The welding might be a problem, though.

[Redwood Chair]

Originally Posted by volvoboy90

Hmm..... I'll look into that. The welding might be a problem, though.

?
Most exhaust shops will tack something together for you for $30-$50.

[smokeyfan1000]

IPD 240 Sport Exhaust is about as cheap(money wise) as one can do an *ALL NEW* cat back exhaust system on a 240.

Back in 1997 it cost me 200 bux for cheapo muffler shop cat back 240 system with universal muffler and all in 2"OD pipe, at the local "Muffler Shop". Fit was poor, they snapped a ex. mani stud, and the Universal muffler was pretty damned restrictive too.

If you plan to keep the car 5 more years or more, an IPD Sport ex. system is about as cheap as it gets (money wise) and it's mandrel bends & appears to me to be pretty good quality kit IMHO. (I bought one & sold it in FS)

And you won't have to worry about possible deadly exhaust leaks, or passing state inspections due to bad ex system.

Buy a MagnaFlow 53000 series cat, as this series is very close to same dimensions/size as OEM cat, and is available in 2"/2.25"/2.5" in/out pipe diameters. I bought my 2.5" cat from www.summitracing.com *AFTER* looking up the part number on MagnaFlow's cat website page. Here is the link for you. > http://www.magnaflow.com/02catalytic...IC%20CONVERTER

Pay attention to the location of your 240's Oxygen Sensor as Volvo moved it's location over the years a bit. On my 91 LH 3.1, the OEM OS location was in the cat itself. And consider replacing the OS while you're at it. Get a BOSCH unit.
Most very early 240s have OS in ex. mani and in header pipe/before the cat in "mid years" 240s, and as mentioned in cat on some LH 3.1 equipped 91-93 models(IIRC)

You can determine LH 2.4 or LH 3.1 by VIN number. Or by just looking if you know the diffference.

Also inspect your header pipe closely especially the welded on bracket spanning the 2 secondary pipes that allows it to be bolted to the bell hsg's bracket.

They love to rust/break there. If needed a OEM Volvo header pipe is BEST, as aftermarket one's are made poorly/very restrictive in the "collector" portion of it I have pics of how restricitve a Starla header pipes collector is if needed

I opted for 2.5" SS custom system though. My custom set up cost me waaaaaay more than 200+ shpg though

[volvoboy90]

Just replaced the header pipe last year, and the o2 was in the old header pipe, so I had to have one welded into the one I bought... What I am looking at is a magnaflow cat... http://cgi.ebay.com/ws/eBayISAPI.dll...p2045653.m1253 I just had to buy one for my mom's 93 240 and it worked perfectly. All I needed to know, though, smokey. Thanks a bunch for all of the responses, guys.

[smokeyfan1000]

Originally Posted by volvoboy90

Just replaced the header pipe last year, and the o2 was in the old header pipe, so I had to have one welded into the one I bought... What I am looking at is a magnaflow cat... http://cgi.ebay.com/ws/eBayISAPI.dll...p2045653.m1253 I just had to buy one for my mom's 93 240 and it worked perfectly. All I needed to know, though, smokey. Thanks a bunch for all of the responses, guys.

I bought that one 1st exhaust "go around" I did on my car. It didn't fit at all for me. Bends didn't work for mine. Seemed to be welded to pipe at wrong "degree"................when bolted to header pipe, the cat's pipe faced down..............

The universal cat 53000 series cat in 2" will work if welded on. You're likely going to have to have some welding done anyway, But try it if you like...

If I were you, I'd buy the universal 53000 series in 2" and have it welded on to fit, doing away with one of the flanes, as they are not available separately from Volvo. You'd have to cut the ones off your old OEM Volvo cat, and weld them to new cat to keep it a "fully bolt on" cat. Trust me you're gonna have to have some cutting & welding done even with the "OEM fit cat" and IPD system

Or buy the 2.25" cat and have it welded on after I'd also had the 2" collector swaged to close to 2.25" to fit the 2.25" IPD System, and do away with the IPD kit's 2" to 2.25" "funnel pipe" for added exhaust flow.

But that'll cost more $$, unles you can swaged & weld it yourself.................

[nate2k5]

the ipd kit is the starla kit with the first muffler removed and an added straight pipe. nothing fancy or free flowing.

[smokeyfan1000]

Originally Posted by nate2k5

the ipd kit is the starla kit with the first muffler removed and an added straight pipe. nothing fancy or free flowing.

The IPD 240 Sport Exhaust is 2.25" mandrel bends using a Starla Turbo muffler.

I'm unsure if Starla makes the same complete system or not. Stock n/a pipe diameter is 2", and IPD kit is 2.25.

OEM Volvo 240 turbo exhaust is slightly larger diameter than 2.25.

[volvoboy90]

From what I could see from the pic on the ebay listing I pulled up, the flange looks likes it matches in angle with my current header pipe... I was slightly concerned since My mother's flange on her header pipe was free and spun to conform and mine is welded solid... I guess I will have to pull the header pipe so I can cut those darn flange bolts loose. The order for IPD goes in on Tuesday. Wish me luck!

[smokeyfan1000]

Originally Posted by volvoboy90

From what I could see from the pic on the ebay listing I pulled up, the flange looks likes it matches in angle with my current header pipe... I was slightly concerned since My mother's flange on her header pipe was free and spun to conform and mine is welded solid... I guess I will have to pull the header pipe so I can cut those darn flange bolts loose. The order for IPD goes in on Tuesday. Wish me luck!

Looks can be deceiving The OEM header pipe fooled me, as I figured it was just like the Starla in the beginning. Knowing what I know now, I would have started with & then modded an OEM Volvo header pipe, but what I ended up with is as good or better.........

FWIW, a OEM Volvo header pipe's collector is less restrictive than a Starla header pipe is inside the collector.

Likewise a true 4-2-1 header (SAMS 4-2-1 header is a good example here) keeps pretty close, if not a total 100% of it's secondary pipe diameter compared to the more(compared to SAMS) restrictive OEM Volvo or Starla header pipes.

But you are correct bout the Starla's rotating flange for cat, vs the OEM Volvo's welded flage. The Starla flanges looks like a bad leak just waiting to happen IMO, and why I cut it off and welded cat to header pipe, but the "cat back system" bolts to cat.

It's what's inside/what you can't see until you cut them open that hurts performance on the Starla header pipe

I modded my Starla header pipe because of this bad restriction.

Also, collector outlet needs to be as close to 2.25" diameter as possible to make the most of the IPD Sport Ex. System.

OEM header pipe, has all mandrel bends and both secondary pipes dump into collector keeping thier almost all of their same "upstream" diameter (primary pipes are actually the cast iron manifold part on stock n/a system, I am using " 4-2-1 racing header terminology" here)

SAMS 4-2-1 header of course has all mandrel bends & as mentioned above the SAMS 4-2-1 header keeps 100% of it's secondary pipe diameter inside the collector compared to OEM Volvo or Starla header pipes.

The Starla header does not have mandrel bends & it's secondary pipes are reduced to exactly 1/2 their original "upstream" size inside the collector ..here see for yourself, here's what I found when i cut open the Starla pipe .............


And I plan in the near future to mod my secondary pipes & collector again, to make it like the SAMS 4-2-1 header's collector is


Looking into Starla header pipe's collector from the secondary pipe's ends



OEM collector looking in from secondary pipe end. (and thanks to 1983_240 for this pics):nod:



FWIW, here's pics of my current header pipe mod, 2.5" in/out MagnaFlow cat and 2.5" SS mandrel bends custom exhaust using 2 different length & outside diameter cased MagnaFlow straight through mufflers, & I used an "L" taipipe as opposed the the OEM "S" style tailpipe on my 91 244. And it is a rather very expensive system too.

I just prefer stainless steel. And I wanted "NO RUST" as I'm a detail/clean freak. LOL This sytem flows great, and is pretty reasonably quiet, but with a "sport" sound.

In case you're wondering......RJ's Custom Piping, in Raleigh NC built this sytem for me, per my specsifications

[impolvo]

Originally Posted by Redwood Chair

Go to the JY and jank a 60mm one off of a 240T for $35.00.
It's what we do in Cali.

they hack em all off here, sux

[volvoboy90]

The unfortunate thing here is my restrictive budget and no welding skills, nor access to a welder or anyone who would do it for me on the cheap/free. I just need at least something that will work for now, and at least come close to doing it right. I went and looked at the flange on my mom's 245 and the flange with the cat attached is the exact same way of the orientation of my flange so it SHOULD work since I will be buying it from the same seller what a coincidence, Summit Racing's store on ebay.

EDIT: Very nice welds on that exhaust btw.

[smokeyfan1000]

Originally Posted by impolvo

they hack em all off here, sux

And if not hacked off, they are crushed by the forks on the front loaders they use to move the cars around the yard at most JYs in NC.

[smokeyfan1000]

Originally Posted by volvoboy90

The unfortunate thing here is my restrictive budget and no welding skills, nor access to a welder or anyone who would do it for me on the cheap/free. I just need at least something that will work for now, and at least come close to doing it right. I went and looked at the flange on my mom's 245 and the flange with the cat attached is the exact same way of the orientation of my flange so it SHOULD work since I will be buying it from the same seller what a coincidence, Summit Racing's store on ebay.

EDIT: Very nice welds on that exhaust btw.

They are TIG welded. Just use an OEM volvo header pipe, the Starla one SUCKS, the diffference is INSIDE the collector.

[Ryan_R]

IPD kit is Starla last I checked. Starla simply is junk, IMHO.

OEM Volvo cat back is best.

Any reason NA performance folks don't run EGR stuff?..... not gonna be as good as custom, but also not as pricey.

-Ryan

[smokeyfan1000]

Originally Posted by Ryan_R

IPD kit is Starla last I checked. Starla simply is junk, IMHO.

OEM Volvo cat back is best.

Any reason NA performance folks don't run EGR stuff?..... not gonna be as good as custom, but also not as pricey.

-Ryan

Have you priced an OEM 240 Volvo cat? I did, $800.00+at dealership,(for my 91 244), hence the the MagnaFlow cat recommendation. Not bad for less than 80 bux, IMO

Also Starla header pipe sucks, OEM header pipe is much better made

The n/a 240 IPD Sport Ex system is 2.25" diameter pipe and the piping is made well and uses mandrel bends.

The "ordinary' Starla systems for n/a 240s are 2" pipe. The IPD kit is a pretty good deal at 200 bux + shpg IMHO. You're not gonna save any more having a mufffler shape make it for you.

Also, if I used the n/a IPD 240 2.25 Sport Exhaust, I'd utilize a 2.25" in/out cat & 2.25" MagnaFlow or other straight through muffler & ditch the Starla turbo muffler. But that'll require welding some hangers/rods on the MF muffler.

As in the usual n/a 240 exhaust system thread goes, here on TB, ...The OPs never have the $$/welder/desire to do it in a fashion where the most possible gains can/will be seen It's always a "buy cheap, bolt on & run deal".