Thermal 2.5" exhaust

[BAD430BENZ]

Anyone out there have the Thermal exhaust without resonators and have downpipes ?

 

[Nick P]

I have SPD's and am replacing my stock Mid-pipes with the Thermal Mids. Just haven't had a chance to install it yet.

You're going to have to cut/expand!weld the 3" SPD's which are built to direct-bolt-on to stock 2.25" system... The Thermal is a 2.5" set-up.

I also Already have Borla S-Type's on it so I will also need to reduce from 2.5" to Borla's 2.25".

Kind of a customized/Frankenstein of existing after market exhaust components, but I already had the DP's and Borla installed. With the, Whipple and Tune...the stock Flex Pipes rattle like Maracas

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[BAD430BENZ]

So you are going from 3" to 2.5" to 2.25"

 

[Nick P]

Correct... specifically due to the fact that I already dropped $1,500 on the Borla S-Type's (with Install) AND $1,400 on the SPD's (Installed 30 days later due to back order).

The 1st run Borla's in July 2020 had a few issues:

1. Bolt Contact Fitment issues with the mufflers scraping against the subframe bolts.

2. Resonator Defect where ALL of the fiberglass packing deteriorated over 3 months causing drone and it to sound waaayyy louder than it should have. (*** Due to these issue Borla gave me a Completely "Re-engineered" Warranty replacement - supposedly fixing their known defects.)

3. With the addition of the High Flow Catted SPD DP's...the already known Ford Factory Flex Joint rattle with a TSB in Nov 2020, became markedly worse, making it sound like a tin can POS Honda Hooptie!

I tried several cheap solves to mitigate the rattle/contact issues with no luck getting the sound profile/quality of exhaust system to be acceptable to me. (For the price point I paid and well known vendors I bought from)

I researched just swapping out/welding in Vibrant Resonators and upgrading the Flex Joint to a more rigid Performance Product...but for the costs of materials/Install....it made more sense to go with the complete Thermal Mids.

In retrospect - a full Custom 3" exhaust would have been right the option.

BUT the path I took led me down the Frankenstein approach of mating SPD(3") to Thermal Mids (2.5") to the Borla (2.25").

Now I just need to get it all Installed and will Report back with the results.

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