Short question asked in a long, round-about way...

My '07 C2S was originally equipped with the stock exhaust. I wasn't unhappy with the exhaust, but when another member here mentioned that they had a brand new PSE laying around that they weren't going to use I grabbed the opportunity and bought it for my car. I did the install myself, not bothering to hook up any of the vacuum tubing (as others have done) and was quite happy with the sound of the "hacked" PSE. They really do sound great.

After a year or so the exhaust developed a loud buzzing rattle, worse when the car was cold, and I took the car in to my OPC. Surprisingly, they replaced the PSE under warranty (above and beyond the call, given that it was obviously not factory-installed). They said the inside of the exhaust resonator was "a mess." They didn't hook up any of the plumbing or relay or anything either when they replaced the resonator.

That was a year ago, and to my chagrin the replacement PSE has now started with the same buzzing. Aggressive throttle (rapid increase in RPM) induces a loud and embarrassing buzzing. If I'm light on the throttle it's almost imperceptible.

I have no clue why I've had such bad luck with the PSE. Obviously plenty of people hack their PSE and never have a problem. Just guessing, I'd point to my track time (couple thousand miles a year) and the consequent time spent at WOT with high exhaust flow going through the resonators. I think I'm just breaking the little baffle flap thing loose from the "abuse." That's total speculation, though.

I doubt I can finagle another warranty repair and I'm disinterested in another PSE for fear that the same problem will just come back in another year. I'm considering going back to the non-PSE exhaust (which, naturally, I didn't keep and would have to buy) or aftermarket.

I'm not concerned about power gains at all and I'm very sensitive to droning (being in a cab). Any advice on which aftermarket options make sense? I just want something that sounds on par with the PSE without being ridiculous or annoying.

 

I recommend doing a search for the DIY hack.

"FisterD" can do it for you, or you can take a stock muffler locally and have them do it.

I love mine!

 

+1 on the FisterD idea - I have a set of stock mufflers that he modified. His work is excellent, and the sound is much better than stock and unbeatable for the price.

 

buzzing? I have PSE and at some RPMs I think I can hear a slight rattle in it.
But no buzzing. What is that buzzing like? Can you compare it to anything?

 

Much, much louder than a slight rattle. Sounds like a marble rattling around in the resonator. It's very loud and sounds broken. Once the car warms up it chills to just a buzzy rattle, but when the car is first started it's very bad.

 

Is that at certain RPMs, or anywhere?

 

Did you use the PSE mostly in open or closed mode?

 

I recently had one can of PSE replaced under warranty in my 05S, similar kinds of sounds although more a rattling sound than a buzzing. My mechanic told me this is not uncommon. (I added PSE without wiring it in, although I did have my dealer install it.)

 

Tubi now makes PSE style muffler cans with the valve. Unknown how they sound as opposed to OEM type PSE mufflers.

Deanski

 

+2

For the price you can't beat this hack. I gave away my take-off muffler for someone else to enjoy the sound. I'd be surprised if you couldn't get some donor mufflers from somebody here.

 

http://www.youtube.com/watch?v=Z6JlR8kwZGU is what it sounds like. It's way worse when the car is moving, but you can definitely hear the rattle even idling.

 

The problem with the PSE has to do with the bands that are tack welded on to keep the muffler together. They are undersized for the job apparently, as mine were replaced as well under warranty. After the warranty has expired it is probably easier to simply have the fractures redone, with welds.

The symptoms you describe are spot on with the symptoms I had until they replaced the PSE in its entirety.

 

+2000 on the fister D hack sound is incredible

 

that happened to the pipes on my cayenne tt went with fabspeed bypass and the vibration ruptured the welds on both cross members of the pipes- fortunately with air suspension i cold raise the car and band the pipes back together I imagine the vibration increase with the fabs loosened the weld

 

Nugget,

This has happened to me as well. I unplugged it for a while, did some track time and presto, dead resonator. The dealer said that the welds on the first year 2005 were not as good and the 2006 and beyond (which is what the car has now) will last. Obviously not as many of us are having the problem.

Personally - On my 993 I had a Fister type set up and coupled with the classic air-cooled sound it was glorious.

Thinking of going X-51 header with FisterD exhausts, leaving the cats and resonators (first mufflers) on any thoughts?

Has anyone run this?