Re: CSC backbox
Ok, finally got a hold of my rubber silencer mounts (£3.50 odd each) from dealer and now have the CSC silencer on!
I have to say I'm very pleased with the results. The overall volume of the exhaust isn't really any louder at idle than the original - perhaps a slight bass tone but hardly noticeable. There's definitely more of a bass tone under load up to about 3500rpm, at which point the engine noise takes over. Sitting in the cabin the noise levels are just the same at idle and speed other than the bass note under load which is really not overly noticeable.
Only disappointing thing was that the oval pipe wasn’t in the middle of the bumper cut-out. This could have been spot-on had the longest bar that’s welded to the silencer (to hook on to the rubber mount) had been bent a bit closer to the box. Never mind, got to expect manufacturing tolerances etc etc! Leaves about a finger width on one side, 2 fingers on the other (I have small hands!).
As for fitting the box, took me about 1.5hrs from getting my boiler suit on to cleaning my hands once finished, quite a long time even though I like to think I have quite a bit of experience working on cars! If I'd had a proper hydraulic lift rather than a trolley jack then the job would have been done in half the time as it really was quite awkward working under the car with the suspension etc only a couple of inches off your nose! Also cable-tied my handbrake cable while I was under the car.
Here's my take on the disassembly/assembly:
1) Handbrake on and car in reverse gear (was pointing down a slight slope).
2) Loosened wheel nuts on NSR wheel.
3) Jacked up car with trolley jack with big block of wood under the centre of the car where the rear suspension arms meet in the middle. Placed axle stands under sills in front of both rear wheels (where there’s a circular cut-out in the plastic cover thing) and lowered car on to the stands.
4) Took rear wheel off.
5) Sprayed WD-40 on the clamp and joint from the centre section to the rear silencer. The clamp is actually welded to the rear silencer and can be loosened by undoing the nut. This took a long time as the nut was badly corroded and was quite resistant to rotational forces!! Plenty of WD-40 and had it off in about 15mins. Don’t bother trying to bash the clamp off with a hammer, remember, it’s welded to the silencer.
6) Cut through the rubber mounts supporting the old silencer with beefy side cutters. Much easier buying new rubbers and cutting the old ones off as the hardened rubber would have been very difficult to slide off.
7) Plenty more WD-40 on the exhaust joint to ease separation. Plenty of pulling and wiggling had the silencer off, eventually! Definitely a 2 man job here. Take a well deserved breather as your arms will be aching!
8) Cleaned up the centre section joint with some petrol and a rag. This’ll help the exhaust paste seal better.
9) At this point I smeared some copper grease over the rubber mounting points on both the CSC silencer and the mounting points under the car. This’ll help get the rubber mounts on. Push the rubber mounts onto the respective bars on the new silencer.
10) Smear some exhaust paste over the mating surface of the centre section pipe that’s already been cleaned.
11) Once under the car with the new silencer, feed the silencer up through the suspension (following the same route the original box took) and mate over the centre section pipe (dad to pull the centre section a bit to line it up). Don’t worry about getting the silencer right over yet, hook the new rubber mounts up onto the car body to support the weight of the silencer.
12) Keep twisting and rocking the silencer over the centre section until the little stud on the centre section stops the silencer from going any further. Take a breather as your arms will be getting sore again at this point!
13) Get your 54mm exhaust clamp (that you’ve bought from Halfords for £1.49) over the joint and tighten the nuts. I would apply some copper grease over the threads to make disassembly a bit easier in the future!
14) Crawl out from under the car and take off the protective tape from the tip of the silencer.
15) Put your wheel back on, jack up the car, remove the axle stands, lower the car and tighten up the wheel nuts again. Remember and remove the locking wheel nut thingy-ma-bob!!
16) Start the engine and after about 2mins the exhaust paste will have cured and bob’s your uncle, one CSC silencer on your AR147.
Photos to follow when I get them taken (possibly thursday!)