Elise S 2ZR-FE Re-Packable Race Exhaust
This car is becoming very popular for track/race use. Once you fit a straight-thru performance exhaust, you realise how NOISY it is! With frequent track use on a supercharged motor, you will need to Re-Pack the silencer if you want to meet the tough UK circuit noise limits. R&D is on-going and I think we might need to fit the Silenced De-Cat Pipe as well, for some circuits - will let you know! Feedback from owners on this exhaust has been very favourable, with no problems reported.
The cheap/rigid exhaust mounts place a huge load on the hanger brackets, so I've moved them to a saddle-clamp layout. These have an in-built flexibility to isolate the system from excessive engine/transmission movements.
The silencer body is made from 0.8mm thick stainless steel. The inlet end-cap experiences the most stress, so the silencer is double-skinned at that point and the end-cap is welded in place. It's a slightly different layout than the 2ZZ-GE install, as I have to lift the silencer clear of the revised diffuser/clam.
The removable outlet end-cap is a 2bular pressing with a tapered flange to ensure a good seal once it's pushed home. I now use stainless pop-rivets to hold the end-cap - quick/easy to replace - threaded fasteners tend to gall (seize) when exposed to exhaust heat.
I use the double-skinned inlet end plus another baffle-plate to form a Helmholtz resonance chamber (H1 version). This drops the noise-level another 5dbs approx. It's a real PITA to fabricate/weld but it works very well.
The Thru-Diffuser pipework is removable to make the re-pack task easier - held with a very secure V-band connector.