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RSR exhaust image for the Porsche 993

The RSR Muffler (NO LONGER OFFERED)

"I no longer offer this service."
Mr. P-Car 2018-04-04 at 1:15pm EDT
For 993 NA and Twin Turbo

The name RSR Muffler is something my friends made up for me for my modified 993 factory exhaust. Since my name is Robin Sun, the initials were perfect for what everyone calls it. The RSR moniker was originally used by Porsche to designate the factory lightweight 911, which is still one of the best horsepower to weight ratio cars ever made by Porsche.

Enough talk about the RSR name, I really came out with the RSR Muffler to satisfy my own needs. After months of searching for a perfect exhaust for my 911s (a 1996 993), and trying out several different solutions I came to the conclusion that in order for me to have what I wanted I needed to build one for myself. What I was looking for in a 993 exhaust in particular was the extra 911 muscular growl that was missing since the introduction of the 993, as you may or may not know Porsche tried really hard to lower the noise level of their cars with the introduction of the 993 model in order to meet strict European "drive by" standards. Although this is perfect for most Yuppies, but for an old fashion 911 enthusiast like me this is a nightmare. But in the same time I didn't want to deal with too much resonance and didn't want my car to sound like a modified "Rice Burner" (Japanese cars with big exhaust tips). I wanted a sophisticated mechanical sound and a muscular sounding idle.......

So, the experiment started. I began with a stock 993 exhaust to maintain the factory look. Personally I didn't want to make my 993 look boy racer; they are such elegant 911s that it deserves the classy factory look (personal opinion). After several revisions and months of road test I finally stumbled on the perfect exhaust for the 993, perfect in the sense that it is what I wanted it to be.

In September, 2002 I started to cut the 993 muffler open on top of the original factory welded seam, so once the mufflers are welded back together there is little evidence that the muffler is ever modified. (Perfect for those who wants to keep their car in original concour condition) Here is a picture of the RSR 993 muffler weld. Just as a reference I have had the 993 RSR Muffler on my own car for more than nine years now, there are no signs of cracking or bursting at the welds. With that said, I will gladly replace any muffler free of charge due to any defective welding on my part for the life time you own your 993.

I also want to make it perfectly clear to everyone that I am offering the RSR muffler not as profit based business, but as a service option to other 911 enthusiast out there who just wanted more sound from their 993 mufflers.

Below are links to help you answer any questions you may have about the RSR mufflers:

Testimonials

Did you ever see the movie "Amadeus"? There is a part where Antonio Salieri, the "bad guy" is old and sitting in a wheel chair and comments about Mozart. He says "MUSIC!, it was MUSIC!".

Well Robin, that's how I would describe the sound of your exhaust, both from the inside as well as the outside. The workmanship was fantastic as well. My mechanic praised the welding as well. When I left the shop, all the mechanics and the sales guys were standing outside to watch me take off... and what a take off it was. I could swear I picked up at least 12-15 horses. There was virtually no resonance, the exhaust note was a sophisticated snarl, growl, well, just "Music". The throttle response, combined with the new K&N filters was significantly improved. The tach just seems to "jump" at my command. Coming around the corner, as I slip into second gear and let it out around the bend, I begin to feel like I'm really "killing bugs fast". The sound was about 10% louder but completely more aggressive yet my wife isn't complaining about the car sounding too loud. In her words, "like a souped-up camaro SS".

Yes Robin, you've truly done it (perhaps by accident), but nonetheless, this is just the right level of sportiness you'd want in a 911.

You have made me a true advocate of RSS, the "Robin Sun Special".

After a couple of Inquiries here last month I hooked up with Robin Sun here in Atlanta. Robin has perfected a 993 exhaust modification that is very slick. Essentially, he cuts the muffler open, makes some mods to improve flow, and welds them back together. I listened and rode in his modified car, Borrowed a set of factory "sport" exhausts, and also rode in a Fabiani Gen 2 equipped car(his). Of the 3(sorry Joe), I like the modified ones the best. Not too loud, virtually no resonance, noticeable flow increase. We bolted mine on this past weekend and they work great. Robin may do a few for reasonable $$$. Contact him at mrpcar2004@yahoo.com

Dan....I just went through the exhausting routine of selecting a muffler. Here's what I found:

After asking some questions on the list I got varied responses. Most with Fabiani systems (gen 1) thought they were far too loud. B&B folks were not real happy either, and, of course, Joe fabiani rants about them exploding, etc. Anyway, to make a long story short, I ran across a guy named Robin Sun. Turned out he was local (Atlanta) and he'd worked out a modification of the stock system which sounded promising. Robin has quite a collection of mufflers including the Fabiani Gen 2, Factory Sport, and his own modified stock. I rode in his car with the Fabs, then with his modifieds and I liked the modifieds the best. We swapped the factory sports onto my car and he went to work cutting and modifying (open the cases, open up a restrictor, and weld back together). By the way, the factory sports were not that impressive. His modified system is perfect. Not too loud, little to no resonance, improved throttle response, very smooth sound, factory fit, etc. I've had them on the car for several weeks now and have added a chip (my 993 is a 95 hence chippable) and intake.

The transformation in the car is awesome. Robin's done a system for a guy in Chicago and he's equally impressed. Not too quiet, not too loud, exactly what both of us were looking for. Robin charges a paltry $300 to do the mods, a way better value than $1,000 + for some stainless cans that don't do it any better and will probably be too loud for you.

Like many other proud owners of the fine Porsche marque, I just can't leave well enough alone. I love to tinker and make oftentimes futile attempts to improve upon what Stuttgart engineers have spent 35 years developing. I've had several Porsches and not one of them retained it's stock muffler for long after it found its home in my garage. I have always desired a throatier sound and more power than the stock setup provides. Mostly what I ended up with was the throatier sound; much to the dismay of my neighbors and others sharing the road with me! Then I bought my first 993. Wow! This was somewhat of a different beast. The glorious mechanical noise of older 911's was almost gone and the sound from the tailpipes was nearlyt inaudible. I often found myself stalling the car when leaving from a dead stop. I knew that those stock mufflers had to go. But, no longer was I going to put up with a brain rattling exhaust note that sounded cool for about a day and then just ended up being a nuisance. I investigated alot of options (Fabspeed was #1 on my list), but after I was steered towards Robin Sun and his home made RSR Specials, I felt that I had little to lose. He agreed to send me the mufflers free of charge on a trial basis and if I liked them, all I had to do was ship him my stock mufflers and a check for $300. Robin was a joy to to "business" with and is just a plain nice guy who happens to be a Porsche nut like myself.

Well, having suffered for my poor choices in the past regarding muffler purchases, I was very suprised when I started up my car for the first time after fitting the RSR's. They were much quietier than I anticipated, but the car now sounded like i believe a Porsche should sound. It's almost like what I'm sure Porsche engineers would want the car to sound like if the EPA were to suddenly forget all about noise regulations. Just the right amount of wonderful throaty exhaust note that rumbles behind the car, but never becomes intrusive in the cabin.

One word of caution though. Don't expect big power gains. My seat of the pants feeling is that these mufflers are good for about a 5 hp gain. This is not a condemnation of the RSR's, but rather my disbelief that any reasonable sounding 993 aftermarket exhaust has the ability to actually make the kind of hp increases claimed by those peddling them.

Robin has hit a home run, and I commend him.

Hi Robin

Just a note to let you know how much I like the RSR mufflers I bought for my '95 993. I put the mufflers on the evening they arrived, turned the key, and have been smiling for three days! The sound is AWESOME!!

After researching Rennlist for over a year to make a muffler change, I know I made the right decision. And best of all, the lowest cost alternative on the market.

Horsepower gains? Don't know and don't care! My first time going through the six gears under power was equal to the first tme I got my hand in my wife's blouse! The mufflers fit perfectly, look pure stock, and make

beautiful music without being intrusive. Who said Americans couldn't improve on German engineering?

Ankeny, Iowa

Well, you have another satisfied customer. I can actually hear the engine. And does it sound great. Remember that my original complaint about the stock mufflers was the '96 did not sound as good as my old '86. Well, now it does. Actually it reminds me very much of how the '86 sounded.

It was actually easier to remove and install than I expected. Only about two hours worth of time and I was done. I was so anxious to get it on the road that I forgot to put the engine cover back on. Oh well, I'll crawl under tomorrow and take care of that.

Check's in the mail, or will be by tomorrow. I'll also box up my old set and send them off tomorrow evening. I'll forward the tracking number to you then.

Thanks again, and I'll pass along your web address to all who are interested. Hopefully you'll see more business from the Cincinnati area.

We got lucky with the weather here in Chicago over the weekend, 65 degrees in February! It finally allowed me to get out and take a long test run with my new RSR Special Exhausts. I was not disappointed.

Frankly, my concern had been that your exhaust system would be too loud or harsh. Not the case at all. While you have definitely kicked the sound level up a few notches, It still retains that throaty Porsche growl.

And, when you hit 5,000 rpm and the second part of the Varioram intake opens up, Wow, what a great sound! Much more noticeable.

As far as the workmanship, my mechanic noted the stainless steel welds were very neat and clean. They look like new mufflers. Installation was routine. All in all, he gave them thumbs up. He also liked the sound.

Goldilocks mufflers, not too loud, not too soft, just right!

Congratulations on a great product.

I installed my RSR mufflers this weekend. The install was easy thanks to the instructions that you give on your web site. I did the work at my dads house since he has a better garage and is equipped with more tools than I am. It was kind of cool spending the day with him working on the car.

The mufflers sound great. The car has a deep growl now that is very pleasing. When I was young, my father drove his 1965 Corvette to work everyday. I used to wake up at 6 am in the morning to the sound of him starting the engine, pulling out of the garage, and driving down the street. The sound of the RSR's reminded me a lot of this.

Anyway, thanks for everything. It has been a pleasure doing business with you.

Guys

After a brief meeting in a Burger King car park with John Webster (993 coupe) and Anthony Bradley (993 Targa)last friday, I headed out on Saturday morning to Switzerland via Gert's place in Belgium to fit an RSR and a Front Protection Bar (which I "used" this morning).

A nicer more professional guy you would find hard to find. We started by going for a drive in his beautiful C4S whilst my C2 cooled down. Lunch in a lovely Belgian brasserie was on him (he absolutely insisted!) and then I drove his C4S to listen to the MK1 RSR fitted (It was my first time in any sort of C4 and is very different. The brakes were awesome.) The engine note was great and really made you feel that you were driving a sports car. Back to the garage we chatted whilst he set about my car on the hoist. Difficult tail-pipe bolts were cut off and replaced with new stainless items and the tail-pipes were then polished before re-fitting for good measure. He fitted the FPB and help me convert the projecter headlights from a RHD country to LHD (just flick a switch!). He also pointed out numerous things about my car that I had no idea of. After a test run (more later) We sat in the garden whilst Lin and Brett (his children) practised their English with me and Maureen his wife kept the snacks and chilled mineral water coming. When it was time to leave (about 8 hours later!) she presented me with two sweet goody bags for my four-year-old twin girls - very generous. Forgetting any P-car involvement I had a great day with Gert and his lovely family - I was treated like an old friend. Gert even insisted on my trying the RSR's out and dealing with payment later. The RSR mufflers on my car were listed as Bischoff number 5's which are ex-RS mufflers. The initial impression was that they were a LOT louder but having stalled my 993 on a number of occassions because it was too quiet I think they are just right. I debated quite a while about whether to go Fabspeed etc but the overall low cost (but not quality) of the RSR made them a no-lose option.

In my opinion they are just AMAZING ! The burble is just right, and the sound as you stretch your car through the gears really gives you an ear-to-ear grin (Gert!).

They sound great when you press on but are absolutely normal (although lower burble) in normal driving. Originally I was going to take the motorway all the way home but instead I zapped through Belgium and Luxembourg before climbing into the hills in Germany, France and Switzerland on A roads. (Standing over the river Saar in the German vineyards whilst below Luxembourg sat in the full moon and "C2 COU" ticked away behind me was one memorable moment).

Overall the RSR MK2 has transformed the car. We all read stories about the "actual" bhp gain of performance exhaust systems but I feel that this is (now, for me) irrelevant. The RSR MK2 makes my 993 feel "right" - I now have the sports car I really wanted. It certainly feels that it revs up quicker, and that it keeps you much more informed of how the engine is doing. After a few miles I was able to guess the change-up points within + / - 100 rpm just on the note (the RSR develops a hardened "crackle" after 6150 rpm which sounds fabulous).

Thank you to Robin for the design and many many thanks to Gert and family.

Mike ('95 C2 RSR MK2 Polar Silver)

PS

If you were asleep in a small french Hamlet when a thunder of 993 carrera noise came bouncing down your valley then.. er.....sorry :-) ).

When I first got my 97 C2 last December, it was delivered with aftermarket mufflers. I wasn't aware of it at the time. I soon became disenchanted with the mufflers because of an annoying resonance that occurred at between 2800 and 3000 RPM. I do not think it fair to mention the brand name of the manufacturer. Trust me, it is nobody you know. I am now the proud owner of the Robin Sun's RSR muffler system for my 97 C2. The sound is awesome and aural candy for me as well. The quality of the workmanship on the RSRs is beyond reproach. I also like the idea that the RSRs started out in life as Porsche factory mufflers. Robin gets his hands on the muffler cores, cuts them open like a can of sardines, does his magic, and welds them up. In addition to the incredible sound, there have been three additional repercussions. The annoying resonance is gone. In addition, for one reason or another, the car seems to run a few degrees cooler. And finally, I find I am driving the car a little harder for the sound feedback. Robin ships these systems out on a core exchange basis. Once you have tried the mufflers and like them, you send him the cores and the cost of the RSRs. Everything with Robin is done on a "handshake" basis. I like doing business this way.

Hi Robin: Here are a few thoughts about your RSR mufflers that you can use as my endorsement of your RSR mufflers:

My car is 95 993 black Carrea coupe with 55,000 miles. It is a daily driver often carrying my daughter and me to school and my office which is close by. As we cruise on Interstate 280 on the way from San Mateo to Burlingame (No. Cal), I can now hear what my engine sounds like since I installed a pair of Robin's gourmet mufflers. Even though I stay between 3000-4000 RPM during most of the drive, it is those few times when I punch it to 4500-6000 that I hear my engine give off the nicest wail followed by a modulated growl as the car slows back to normal speed. Those sounds from the exhaust can sometimes be as important to a car nut like me as the first cup of coffee in the morning (the only reason I have my job is to drive my Porsche to and from every day).

The removal of the old mufflers and installation of the RSR's took two of us about an hour and a half. We used ramps instead of a floor jack, and printed out the RSR DIY directions for reference. I am wrench-impaired, and found removing the tips more of a challenge than working with the muffler swap. Robin was kind enough to offer his cell phone number in case we got stuck, but the task and the layout of the 993 muffler system made our task simple. My biggest problem was the WD-40 stains on my shirt.

If you want to hear the engine in your 993, the RSR's will provide the sound you've been missing. The price is right, and Robin's honor-payment policy is a pleasant change in the pre-paid world we live in. He is a nice guy trying to subsidize a hobby that also brings out the best of ours. I am pleased, and so are my ears.

Greetings Robin, Went to Willow Springs Race Track last Monday and drove my 993TT like it was a stolen car and I had just held up a liquor store! The car performed superbly and has me itching for my next track day. I had 2 or 3 other Twin Turbo owners circling my car wanting to know why it sounded so much better than theirs. When I told them about the RSR mufflers, they were turning green with envy and wanting to know how they could get a pair. I gave them the website info and told them to email you. Moreover, since my car already has the PROgram as well as an FVD intercooler, I am convinced that the mufflers do in fact give me crisper throttle response, as well as the awesome sound. Anyhow, I continue to be extremely pleased with my RSR mufflers. My only regret is that I didn't have some good scotch for us to drink when you were out here installing them. Best regards. Rob Wolford

Hi Robin, I had the mufflers installed on Tuesday and WOW do they sound fantastic....I found myself sitting in the car in the car garage just listening to them....absolutely perfect. My original mufflers with all the extra pieces should be on their way to you now. I had my mechanic ship it back in the same box to the Premio address and attention Robin Sun. I'll have a check headed your way today via Airborne so you should see it tomorrow. Thanks a bunch for the great product and service, Glenn

Robin, Just a note to tell you the muffler cores were shipped UPS ground yesterday. I also mailed a money order for the RSRs plus the delivery shipping yesterday. Please let me know when you receive both. Saturday I was able to actually drive the car with the new mufflers. It sounds great with the classic throaty mechanical tune you expect from a Porsche. A friend said I really need to hear it from the outside. My seat or my imagination tells me it's winding up quicker as the higher revs approach. I do have one question. Do the clamps used to connect the muffler and exhaust tips or muffler and catalytic converter pull the two sides tight together as tightened, or do you need to make sure they are pretty tight on the bisket before tightening? Thanks Allot, Barry J. Minister

I went for a quick ride last night. Much better! Thanks for turning them around so quick. The sound is what I was expecting to hear the first time I drove it. Luckily I found someone with a common interest and much more mechanical ability. Good stuff. If you come up with a mod that makes the mufflers sound like a 550 Maranello, sign me up. Talk to you soon.

Robin, the mufflers are on the car today and they sound GREAT.... The changing of the mufflers was simple, I need to know how make the check out Robin XXXXXX? I have the address to mail too. I will be mailing you a check for $650.00 as I will keeping the stock units. The car sound nice not to loud yet having a deeper throatier mellow tone. The level of sound in the car is low and a clean motor sound, if anyone in So. Cal. would like to hear RSR in action have them get ahold of me. I want to thank you for your help in supporting me with the biscuits. How much due I owe you for the biscuits and shipping cost? Also, if I would be of help to someone in So Cal. in installing the RSR mufflers I would be glad to help. Have happy holiday and enjoy your family and your P CAR. THANKS AGAIN JOHN BOUZA

Robin, I picked up my car at the body shop on last Wednesday and left on a 1,000 mile tour of the Texas Hill Country with the local PCA group on Friday. I loved the sound of your mufflers-not too loud, not too quiet. I am mailing my check today and will ship my mufflers in the next day or so. Thank you very much for this wonderful addition to my car. Craig Daugherty

Tito, EJ is absolutely correct. I have a 97C2S which came with Motorsound. I recently swapped out the mufflers with Robin Sun's RSR's and I think it is a significant improvement in sound without being excessively noisy/goofy etc. They growl and rumble beautifully without any change in resonance, a real pet peeve of mine, and I would say they are roughly 10/15% louder than stock which might seem too quiet, but on extended use is just about right for my tastes. And, I do believe a part of the Motorsound sound is the beholed airbox which comes with it, and the resulting intake swoosh. So go to Robin's site below and give them a try. He will send the mufflers to you to try out. Your only cost, if you don't like them (which I seriously doubt) will be a few bucks to send them back to him. Robin's Site

Hello Robin, I received the mufflers Friday, installed them Saturday and enjoyed them Sunday. I am very happy with them and would like to thank you. I think I'll get the motor sound air cover to complete the package and keep everything Porsche stock. The local dealer will install the ROW M030 springs next week with the stock shocks. He claims to have done a number of them, all with positive results. I know the rear shocks will be an 1" too long, but the dealer said he'll cover all labor if I'm not satisfied. Thanks for all your info. Since it's a cab and I have a track car, I'd like to keep the suspension as compliant as possible. I'll get the old mufflers to you this week with the check. Thanks again and if you need any referrals, please include me. Tom

I just got my RSR mufflers from Robin Sun, and I thought I'd report my impressions on the installation and the sound. For those of you that don't know, Robin modifies stock 993 mufflers for a better sound. See: Robin's P-Car Site

First, my car is a '97 C2S with the factory motorsound airbox and stock, non-motorsound mufflers.

The installation took me two hours, which included figuring out how to jack up the car for the first time (thanks to this BBS and Robin's DIY section on his web site), re-packing the old mufflers for shipping, and taking the opportunity to give the exhaust tips a good scrubbing and polishing. The only thing that cost me a little time was that I didn't figure out what the brazed-on clip on the muffler was for until after I had one muffler strap snugged up. I realized pretty quickly that it must be there for a purpose, so I took the muffler back off and saw the hanger that the clip hooks to.

I'm sure it's just my own doofocity, but maybe this will save someone a bit of time. Overall, it was an easy install.

Now to the sound: Perfect. No booming. A pleasant gurgle at idle, a throaty growl under throttle. I was afraid it might be too loud, but it isn't - I just love it. It makes me want to go out and drive it even more than before, to send the tach climbing again and again. The subdued sound of the stock mufflers was a real let-down for me, so this modification has made me feel much better about my C2S - the love affair deepens.

I still wish the car had that whirring mechanical sound of my '87 Carrera, but now my 993 has a rather loveable and distinctive sound of its own that the '87 lacks.

This $350 modification is the best money I've spent on this car. You'll like dealing with Robin, too - he's a class act.

Will

'87 Carrera Coupe, Grand Prix White
'97 Carrera S, Glacier White
'96 BMW R1100RT

Robin - got the mufflers installed w/no problems and love the sound. As everyone else has said - just the right rumble without being obnoxious. Hard to imagine a better $350 upgrade.

I got a tad busy today and didn't get the cores and check out today. I'll send them tomorrow via FedEx 3-day so you should have them by end of week.

Thanks and pleasure doing business with you!

Ben Hartsell
'97 993 C2S
'00 Boxster
Plano, TX

very good indeed. If you are even remotely unhappy with the quiet sound of stock or even motorsound mufflers, dont hesitate to get Robin Sun's RSR muffler solution. I'm a doubting Thomas and had to hear Will's RSRs on his C2S first. That convinced me and Robin delivered mine (modified motorsound mufflers)less than one week after I ordered them. Will installed the "new" mufflers for me Friday. Took one hour. I think he's got it down now. They sound just as I wanted them to be. Not too loud, not too soft. To my ear roughly 20-30% louder than stock on acceleration. Nice enhanced low basso profundo sound with an occasional brap/burp interruption coughed out at engine start and idle. Reminds me of a muscle car with variably variable idle. Nice increase in deep engine roar up past 4000 rpm yet quiet as stock mufflers at cruising speed. No resonance at all. Comparing Will's C2S with my C4S, Robin's QC is right up there with the best of them. Will's and my machines now sound quite identical despite the fact that he has the motorsound air intake and I dont. Therefore, I don't feel the need to install that as well.

Here's the best part: I dropped my 13 year old off at the old movie theater in Ann Arbor when I pulled up to the curve and shut the engine off. Usual Porsche occassional stares. Then after a goodbye hug, I fired the sucker up. Wow! The entire line stared. I felt like 19 years old again. That was priceless. I have that incessant urge to rev the sucker at stoplights now when I'm next to Preludes and Mustangs. Best $350 I ever spent. Thank you Robin!

Richard 1996 C4S arena red

Thanks Robin for the great work producing my RSR mufflers. I would describe the sound as very tolerable around town and on the freeway, but agressive enough when I tip into the accelerator pedal. No highway "BUZZZZZ" like my old B & B, and the quality of workmanship is superb. To cap it off, quick service as well. I fully recommend your RSR conversion to anyone who wants to enjoy their car and the way it should sound.

John
Dublin, OH

Robin,

I hope you are doing well during the tragedy we've all experienced this week. Nathalie and I were vacationing in Florida when the attack occurred, and we just completed a 1,000 mile drive home in a rental car after our flight was canceled.

I installed your RSR mufflers on my 1997 993TT today, and wanted to give you some feedback. As many others have commented, the quality of the welding and craftsmanship is excellent. I agree with you that the mufflers should last a long, long time.

I did have some trouble with the installation, but this was no fault of yours. Two of the four 13 mm bolt/nut combinations were severely frozen/rusted and snapped during disassembly, prompting a quick call to Phil Anderson at Suncoast. I was able to reassemble everything except the tips, which will have to wait until my replacement parts arrive. Also of note: on my car, the muffler strap was held on by a 6 mm hex bolt, not a 7 mm hex bolt as shown in your DIY section. Interestingly, the PET part diagram from Phil shows the part to now be an 8 mm "cheese-hd screw". It would seem that Porsche is using the old Italian method of utilizing whatever parts are handy at the time of assembly. ;)

As you had explained, the sound is subtly different - perhaps 10-15% louder, with a nice change in tonal quality. My wife commented that it sounds "cleaner" and "less choked", and I would agree. The overall sound is a bit more rumbly and lower, with no resonance. The sound is more like my Ducati with the Fast by Ferraci pipes, but not nearly as loud. In addition, the mufflers now allow more of the mechanical sounds to shine through.

It may be my imagination, but the car seems to rev just a bit easier and faster. Of course, I just spent the week in a Budget Rent-a-Car Ford Taurus, so anything might seem more performance-oriented by comparison! :)

Robin, I congratulate you on a job well-done. We'll see if anyone notices the upgrade at the Putnam Park PCA DE event this weekend.

Thanks again for the help. Feel free to add my comments to your site if you desire.

Anir

Robin: Had the mufflers installed yesterday and they are just as you claimed they would be. Not very loud. Just loud enough to give a hint of 911's from the '60's. Its a nice addition. My mufflers were re-packaged in your computer box and should have been sent UPS today. I will put a check in the mail tomorrow for $360. Please tell me how you want the check made out and which address to send it. Thanks ! BruceB.

Robert: Just got back from my first drive with your RSR mufflers. Way cool. It is soooo nice to be done with the resonance from B&B Tri-Flo mufflers. Your solution is bullet-proof. Nice rumble down low, nice wail up high, and no resonance! This is what everyone should be trying to build. My mechanic will be returning the core Gillet mufflers today. But I forgot to write down your address. Can you tell me where to send the check?

Ric Vieler
Software Engineering Manager
Saratoga Systems, Inc.

Oh yes, "the sound."

1st, Let me tell you what I was looking for... I think of the 993 as a "classy" version of Porsche venerable 911. I therefore wanted to have an authoritative rasp when I hit the key, and perhaps a mild tone as I idled away from a crowd - but not much more. Obviously I was attracted to "motorsound" versions for just that reason. However, what motorsound lacked was the "mechanical" tune that I heard your magic could offer...

So here is how my first moment went.

With great anticipation after install I walked from the back of the car (I took a bit of extra time resetting the twin tips to suit me) and to the key. I had just completed a similar swap a few weeks ago (as you know) w/ my faux motorsound system I mistakenly bought. All I could think about was the time I hit the key after putting THEM on - and then of course my great disbelief when they sounded the same. Anyhow, I reach in the cabin, and I hit the key...

The 3.6 liter then roared to life with no effort & a harmonic tone unlike any that I have ever heard. I jumped from the door sill & ran to the back of the car as to "take it all in." It was "the sound" I was looking for Robin. Authoritative, classy, above & beyond good 'ol motorsound. A true musical note and absolutely not obnoxious in any way. 100% socially acceptable & truly an addition to the cars overall value.

I then took the car for a quick jaunt & found that the interior noise level was low, just as I had hoped. I also had a chance to give the car a strong run up the gears & found myself breaking the tires loose unlike I had ever before. A fluke? I dunno. Quite possibly a result of the RSR muffler.

After zipping back in the driveway I ran in & asked my wife "is that loud?" She says "No no! You just HAVE TO hear this!" She jumped in the driver seat & left me standing at the curb. As she pulled away, I knew that all the RSR rumors I had heard all had merit. It was an outstanding sound, and I had only one guy to thank.

That guy is you Robin. Let me personally say thanks for all your R&D, and for all of your efforts to make this one of the most satisfying swaps I have ever encountered. It is the "right" 993 addition.

On a side note, after dinner tonight I had to go listen one more time. This time I left the garage door down and hit the key. It was grand. I rev-ved the car a few times to enjoy the tone, then shut her down and just smiled. Great job Robin.

Thank you.

Michael

Hi Robin,

Yes. I developed a "headache" at about 4:00PM yesterday and went home. I heard that lying down would help. Well, I didn't make it into the house, so I laid down on the garage floor. Since I was already there and the tools and muffler were just sitting there I figured to make use of my down time...90 minutes later my "headache" went away. It was a miracle! I can only attribute that to the soothing gurgle of my new RSR mufflers! So you can now advertise that it cures the common headache! I took it out for a run (again to ensure that my headached was indeed cured) and couldn't be happier with the sound. I must have looked silly driving along rolling the windows up and down randomly to listen to the car. I'd describe the sound as a sweet, raspy, mechanical gurgle (not too loud, but just loud enough) that gives my car a voice to say "Let's rock!" (and cures the common headache!) Whereas, with my Motorsound or RS mufflers it was more like, "Shhh...we mustn't disturb the neighbors...lets wait until we're on the highway...afterall we've been refined for over 35 years".

The RS mufflers did seem to have a lower tone but no other distinguishing characteristics. I will keep the RS mufflers though for when I experiment with opening up the entire exhaust and intake. And the Motorsounds will be my backup. So...does that answer your question? My cores and payment (payment will be sent "snail-mail" in case UPS does an "oops" with the shipment).

Kim Ouye
Silver "Gurgling" Bullet

Hi Robin,

I just wanted to add a little something to the plethora of plaudits you have regarding the fabulous RSRs - but from from across the pond, here in England. All the quotes on your site are from US based customers who are all very happy indeed, but I didn't see any from any European based customers - so here I am with my 2 pence worth.

As you know, Gert Carnewal handles the European RSR distribution and the guy is truly magnificent in his approach and service. He kept me posted on how long the wait for my RSRs was all along and they arrived very well packed, containing new bolts for installation. After having followed your instructions, I fitted the RSRs myself on a quiet Sunday and all I can say is that both myself and my brother (who stood and watched me fit the mufflers) were truly astounded by the noise. We both just smiled that knowing smile when you know that something is so right. Although the sound is louder, I wouldn't say it was loud, but definitely deeper and far more 'woofly' (is that even a word?).

This really is a great product and I can heartily recommend it to anyone considering a more noticable - more Porsche - sound from their 993. Robin, thanks for having the brains to put this together and the ingenuity to get the operation off the ground and across to Europe.

Mind you - none of the european boxes are as shiny as the ones the US guys get!!

Brilliant!

Surj Sandher

Espeed

Hi Robin....Work has been killing me in the past while. I'm sorry its taken me so long to get back to you. I would like to take the time and thank you for being such a great guy to deal with. You are very honest, super trusting and patient. As for the RSR Muffler....it's great! I cant stress more how well made it is and the quality of sound is excellent. Not too loud for everyday driving and loud enough to enjoy the 993 as it was meant to be enjoyed. It is not headache causing nor obnoxious. I personally would have liked a bit more WOT scream but I wont sacrifice the noise level for everyday driving. My only beef with this exhaust would be a little droning noise at about 2500 to 2900 rpm on 1/4 throttle at a cruising speed inside the car. I am suspecting that my sport air intake is also a contributing factor to the droning noise. Out of 10 this bothers me about a 1 out of 10. When I first got the exhaust on the car....I thought it could be louder but after 1000 klm, I realize that it is just right. The best part of the whole exhaust is the sound when it is idling....THAT'S PORSCHE !!!

The bottom line.....

I would do this again without hesitation.

Value.....can't beat the price!

Installation....1 hour and 3 out of 10 on the difficulty level. You wont need any special skills here. I followed Robin's instructions and it was simple.

Robin.....A stand up guy. Open honest, a true lover of the sport and Porsche. I don't know how he put up with my 1000 questions.

Thanks once again Robin.

Albert Lee

Toronto, Ontario, Canada

Hi Bill....sorry its taken me so long to get back to you. I got caught up with New Years plans.

HAPPY NEW YEAR !

So far I only have about 5000 klm on the RSR Exhaust. Most of the milage I have put on going to the track and on the track. The exhaust is pretty much flawless. The interior noise level is excellent. You can hear it but it never becomes an head ache. Outside the car its like music. From the second you start it and drive off. It has an amazing sound at idle and a better sound while driving. If you stand outside the car and rev the engine the sound is agressive but not loud. This is an exhaust that will not put you on your neighbours BAD LIST. For my taste I would have like something more obnoxious and loud but at the same time, this is as much noise that I can handle without being uncomfortable. So to sum it up, The RSR exhaust makes my 993 sound like what it should and is perfect for my needs. For the price you can't beat it. If you want something crazy loud, the Fabspeed Cup is the only way to go. Robin was a great guy to deal with. Not many people like him anymore.

Good Luck Bill,
Albert Lee

I installed my RSR mufflers Saturday and they are awesome. I have removed all of the sound deadening padding from the engine bay and can hear the mufflers even at idle. I have had RSRs on other 993s, but still had the sound pad in the engine bay. They have a great burble at idle and just the right amount of raspy bark under load. It is the perfect blend of sophisticated exhaust sound without the boy-racer listen-to-me drone. The best part of all is that when driven conservatively, it easily passes the wife test!

Thanks, Robin and Merry Christmas to all!

Hank Cohn

FAQ
Installation
Read the most comprehensive review of the RSR muffler by Jim Calder

Outside of the North America

993 owners outside of the N. America continent, the RSR muffler solution is also available through a fabricator in Belgium.

Please contact Gert Carnewal in Belgium for more information.

There is absolutely no obligation with this, if you don't like the way it sounds you can always ship it back to me and there will be no charge. The only expense to you would be the freight charge to ship the RSR mufflers back to me and the labor charges to have the muffler installed and removed. (If you have someone else install the muffler)

A word of caution, the RSR 993 Muffler is not going to be very loud. Upon start up there is a little more rumble, and there is a gradual increase of mechanical sound through out the RPM range. The top end sounds even better. And don't expect any big horse power gains either, this exhaust mod will definitely help your engine rev a little faster through all the gears, but I refuse to believe changing out the muffler will give you 15-20 more horse power. The RSR Muffler in my opinion is a nice sound you just grow to love. But if you want something to terrorize your neighbors with the RSR Muffler is not loud enough for that.

If you are interested and want to give it a try please let me know right away so I can put you on the waiting list. Please check the FAQ section for detail ordering information.

Below are some brief explanation of the RSR muffler modification process

The process to make a RSR Muffler unit from a factory stock unit takes about 5 hours for the pair. The first process is to clean and polish the outside surface of the muffler, the outer surface must be clean of any debris or contaminates before it can be cut open with a plasma cutter, the surface also needs to be clean in order for the welds to be strong. The plasma cutter method of cutting metal provides one of the cleanest cut possible on the stainless steel metal, short of cutting the muffler with a laser gun it is by far the most high tech method of cutting any metal. The learn more about the plasma cutting process click here

A diagram of how the plasma cutter works

Above - a diagram of how the plasma cutter works

This picture shows the clean cut line done with a plasma cutter

Above - This picture shows the clean cut line done with a plasma cutter.

The next step is to split the muffler open, I fabricated a special tool to ease the splitting process. Once the muffler is opened I go to work on modifying the pipes inside. Once the pipe modification is complete I grind up the edges of both open surface with an angle grinder to make sure there are no contaminates on the surfaces to be welded. (The rule about welding preparation is that you only use brushes and grinding pads specifically for one type of metal, can't use the same pad to grind steel and then grind stainless steel, because of the cross contamination)

This picture shows the differences in the metal surface after a light surface grind

Above - This picture shows the differences in the metal surface after a light surface grind.

What makes stainless steel difficult to weld is that stainless steel are a much poorer conductor of heat and so the temperature of the welding spot can grow hot much faster since the heat is not carried away. As the temperature gets higher you obviously get more expansion, per unit of energy injected say that is injected into the weld. This is what makes it awkward to weld, the conduction properties not the coefficient of expansion which is in general about 6 parts per million per degree C. Which means in order to weld the muffler halves back together I must strategically position the tack weld around the two halves of the muffler before I can start the actual welding process. The tack welds must be welded on in balance, in other words a tack weld would need to be welded on right after a tack weld in the opposite side of the muffler. This is the process where you wished you have 3 hands.....

http://p-car.com/ferrari/diy/clutch/album/

Tac welds spots

Again because of the property of stainless alloys, the only right choice of welding method to use is a "Gas Tungsten Arc Welder" (GTAW), I call it TIG (Tungsten Insert Gas) welder for short. TIG welding is a commonly used high quality welding process. TIG welding has become a popular choice of welding processes when high quality, precision welding is required.

In TIG welding an arc is formed between a non consumable tungsten electrode and the metal being welded. Gas is fed through the torch to shield the electrode and molten filler rod. A TIG welder's main benefits are superior quality welds, welds can be made with or without filler metal, precise control of welding variables (heat), free of spatter, low distortion.

TIG welding diagram

The final process is to complete the welding around the two halves of the muffler canister one bead at a time, and each canister takes approximately 1 hour to weld back together. And because the TIG welding process is a very clean welding process and free of spatter only a light stroke with a stainless steel brush is required at the end to complete the welding process.

welding process

This picture was taken during the welding process

picture of some completed RSR mufflers

Here is a picture of some completed RSR mufflers

August 2001 issue of 911 & Porsche World - Mention

This is the same exhaust system that was mentioned on John Stewart's running report in the August issue of 911 & Porsche World magazine.

My RSR muffler was mentioned on an International Porsche magazine!

Most of your guys know that I have been making custom modifications to the Porsche 993 exhaust system for the past three years. It originally started out as little weekend hobby has now turned into a steady stream of requests from all over the world. Besides having my RSR exhaust system shipped all over the United States, I also have my RSR exhaust system installed on Porsches in Switzerland, Belgium, New Zealand, and England. For all the European customers I pass on the rights and the responsibility of making the RSR muffler to my friend Gert in Belgium. He basically take cares of all the RSR muffler from the other side of the pond. (Personally I didn't want to be bothered with shipping products Internationally)

I don't advertise these exhaust system that I build, every system sold is through word of mouth and referrals. All I have is a little web site that describes the system and it's function and ordering information. Click here to see that page

Recently to my surprise my RSR muffler system was mentioned on a well known International Porsche publication!

I thought I share this with you guys.

cover of 911 and Porsche World from issue number 89

This is the August issue of the 911 & Porsche World

Here is the article where my name was mentioned.

John Stewart the contributor of this article lives in England, we have exchanged various e-mails in the past regarding different issue with his 993. And John is the one that mentioned my name and my RSR exhaust and my web site in this article. (Click on the picture for a close up look of the paragraph where my name was mentioned)

photo of the page inside of issue number 89 of 911 and Porsche World

My findings and experience with the purchase and installation of the RSR muffler system

Jim Calder
1996 Porsche 993 C4S (Wide Body)
59000 original miles

photo of the exhausts sitting behind Robins 993

I am now the proud owner of the RSR muffler package that is now installed in my 1996 993 C4S.

To my delight, I was able to order the muffler package over the Internet (via Robin @ the P-Car website) and was able to do so without any financial obligation. The mufflers were sent to me freight paid and I was able to evaluate them prior to making any payment (including the shipping). Needless to say, this was a ‘no-brainer’ in terms of ordering the system.

I was quite fortunate in that the Gillet style mufflers were readily available from Robin. My wait period was only about 2 weeks. Upon receiving the mufflers, I would have to say that everything was completely in check with respect to the RSR documentation on the website. The modifications, original muffler integrity, and welding all appeared to be first rate. As a general observation, it appears that Robin does very well in matching up the original mufflers. As part of the deal, this is done on an exchange basis. The muffler type, vintage, and approximate miles/usage are matched very well. In a nutshell, not even an expert could tell any visual difference between the original mufflers and the ones provided under the RSR flag. There is one exception worth mentioning and that is the RSR mufflers receive a great deal of attention in terms of cleanup. The mufflers that I received had been swirl sanded/polished to a nice satin finish. There is a picture on the website showing the cleaned and finished mufflers. My mufflers looked exactly as shown on the website. One last comment on the finish: The cutting and re-weld was done at the rear seam of the muffler where the factory weld bead is located. Upon reassembly, welding, and cleanup, there is virtually no evidence that the mufflers had seen some massaging. These should pass for any show-car events where OEM requirements are in place.

As far as installation is concerned, it is as easy as it gets (at least for a muffler installation). The factory flange fittings and bracketry make for a reasonably easy job. One important note to make is the heat shield installation. My shields (which are in great shape) were transferred from the old mufflers to the new when all mufflers were out of the vehicle. This is quite simple with only 2 10mm bolts to contend with. However, after a few miles of driving, I had rattles and vibrations with the shields. I believe that this is due to the resonant frequency of the mufflers changing slightly (probably moves down a few Hz). Not a real issue. All that is needed is to put a slight twist in the shields prior to installation such that there is a slight residual stress. There may be better ways to deal with this and it may not be an issue on everyone’s car. My suggestion: After installing the shields on the new mufflers, and prior to installation, knock on the side of the muffler casing with your hand like you were knocking on a door. If you hear the shields rattle, eliminate it at that point (per the above suggestion) or by some other damping technique. If the shields make no noise and the knock sounds like a thud….then you are good to go with nothing to worry about. The shields are thin stamped aluminum and they do not take too much to make noisy or silent.

On with more important things:

The sound of the mufflers (with the stock tips) is just as Robin describes them. (In my opinion) they make a Porsche sound how a Porsche should sound. The following is a brief summary:

  1. Sound at idle outside the vehicle – The sound is much throatier. On a relative scale, I would say that the decibel level increase is less than 4db at 1 meter. This is purely a guess in that I do not have a sound meter. One might say that it is ~ 15% louder? In any event, it is a nice increase but is not loud or annoying. It is a deeper more metallic sound. I have used many mufflers for race and street. My best analogy is that the sound is half way between the stock mufflers and a 3-chamber Flowmaster muffler. Flowmasters are quite unique with a metallic-open sound and I think that the RSR muffler is very very close (but significantly quieter). I also have a few friends that agree with the Flowmaster sound comparison.
  2. Sound at 3000 - 6500 rpm outside the vehicle - My review here is not that accurate in that I have only heard one alternative driver in my car with me standing outside. It definitely sounds beefy. The sound is as referenced above. I would equate the sound to be very close to a 3-chamber Flowmaster but not as raspy or loud at the extended RPMs. My guess is that the sound is up by about 6 db to 10 db at 1 meter for the lower and higher RPMs respectively. The higher the rpm, the more aggressive the sound. Most of my evaluation here is hearing the reflected sound off of buildings as I scream pass them. I feel that the sound is very appropriate and pushes the db level only to a point. I believe that it is quiet enough not to attract attention from ‘Johnny Law’ (knock on wood so far...). When it does become loud enough to attract the “Law” you are already exceeding any posted speed limit within the US…so who cares...) RPMs in excess of 5000 rpm will notify anyone around that there is a Porsche in town. There is no mistaking that the Porsche now sounds like a Porsche at RPM. It sounds good and definitely turns heads.
  3. Sound at idle in the vehicle - Robin told me that there was a small increase in interior noise. Frankly, I disagree. My finding is that the interior sound at idle is nearly that of stock. Bottom line…it is quiet with no noticeable resonance. The valve train makes more interior noise at idle than the mufflers…what can I say. I think that this is a very strong selling point here. After all, who wants to sit at traffic lights (or take out a date) with a strong droning noise that gives you a headache. If there is any increase in interior noise, I only detect it from the outside sound when the windows are down.
  4. Sound at 3000 - 6500 rpm inside the vehicle - It is surprising that the sound pressure levels only increased slightly. It is very reasonable. Most of the increase in sound is from outside the vehicle. From a resonance standpoint, I would say that it is very close to stock. One might say that there is maybe a ~25% increase in noise at the higher RPMs. The noise level is what I would consider acceptable. A person can still communicate. (Unlike with many performance muffler systems)

The only other notes that come to mind are related to performance. As Robin claims, and is likely the case with nearly every other performance muffler, there is no significant gain in horsepower relative to the factory setup. Anyone making such a claim for a stock motor is full of *#*#! If the motor is modified with headwork, cams, and elimination of the catalytic converters, it is reasonable to conceive that horsepower gains are significant with a change of mufflers (but that is not the case here). However, there is a performance increase. After the installation, it was readily apparent that the motor is more reactive at the higher RPMs (4000-7000). Possibly this is due to less stagnant regions of air within the muffler or better laminar flow??? That is my guess. The bottom line is that the motor is much more responsive to throttle ‘blipping’ for down shifting. It is as if about 4 pounds were removed from the 28-pound (or whatever weight it is) flywheel. Prior to the RSR install, I found that I had to hang the throttle a bit longer for proper gear meshing. Now, one quick stab of the throttle gets the job done. (The day the motor is dropped I will definitely be replacing the “Anchor Flywheel” with a light performance version…I am used to flywheels less than 10 pounds in my SCCA racers)

Anyway, glad I made the purchase. Thanks Robin

Jim Calder

jimc@socal.rr.com

Installation - How to change the muffler

These procedures will show you how to remove the factory muffler from your 993, the installation is the reverse of these steps.

Basic tools needed to complete this job:

Step 1

Loosen the 13 mm bolts that holds the exhaust tips on.

photo of exhaust tip removal

Step 2

After removing the bolts, use the snap ring pliers to spread open the flange that secures the tips to the muffler and remove the muffler tips.

photo of snap flange

Step 3

Loosen the 13 mm bolt that is on the flanges on the other end of the muffler pipe that attaches to the CAT.

photo of cat bolts

Step 4

Use the snap ring pliers to open up the flange and slide the flange so it rests on the CAT side. This will save you a step when installing the replacement muffler.

photo of muffler hanger

Step 5

Remove the strap that holds the muffler in place, on the 95 993s that strap is held together using a 13 mm bolt, on 96+ 993s the bolt is a 6mm hex bolt. Slide the strap out of the way and lift the muffler up from its clip and the pipe that is resting on the CAT. the muffler will drop down.

Step 6

This step only applies to RSR Special customers, I do not include the heat shields on the RSR Special when I send them. You will need to remove the heat shield on your original muffler using a 10 mm socket to remove the 2 bolts and remove the bolt clip underneath it and transport it over to the replacement muffler.

Installation procedure is the reverse of these steps. When mounting the exhaust tips back do not tighten the bolts all the way, leave enough slack so the tips are still moveable. Once the desire position is adjusted tighten the bolts down.

P.S. The mystery muffler on these pictures is the Fabiani 2nd generation system. Donor car for this DIY is my 96 993.

FAQ

Here are some Frequent Asked Questions about the RSR mufflers, hopefully they should answer all of your questions regarding this exhaust modification. Please feel free to contact me at my e-mail address mrpcar2004@yahoo.com if you have any additional concerns or questions.

A: - Please e-mail me your ship to address, day time phone number, year model of your car, VIN number and the current mileage.

993 owners please also take a look under the muffler to see what brand of stock muffler you have, the brand is stamped on the muffler canister it is either a Bischoff or a Gillett brand. Starting July, 2006 I have decided to discontinue the "try first pay later" policy as the number of dead beats are increasing. So I will accept paypal as the only method of payment for all future transactions. Please paypal me the correct amount according to the below payment schedule prior to me shipping out the muffler. Once I have received the core muffler return the core deposit will be refunded via paypal. Please also take a moment and read through the rest of the FAQs.

Here is the payment schedule:

The core charge is $300 for the 993 muffler, the 993 turbo is $500. Your core deposit minus the shipping charge will be refunded back to your paypal account once I have received the core muffler return from you.

Here is an example of how it works (shipping charge is an estimate)

Say you want to try out a set of 993 NA RSR muffler. First e-mail me the information on your car, once I have confirmed back to you that the muffler is ready to ship then you will need to paypal me $750. If you decide to keep the RSR muffler then go ahead and ship the old core muffler back to me. Once I have received your core return I will refund you the core deposit of $300 minus the freight charge for me to ship you the RSR muffler. For example if the freight charge was $45 then you will receive a refund of $255 ($300 - $45 freight) back to your paypal account.

You have 60 days to return the core muffler once you have sent me the paypal payment, as that's the number of days I can send a partial refund payment without a penalty. So any core muffler that's received after 60 days is subjected to a handling fee.

If you are not familiar with the paypal system please visit their web site at www.paypal.com.

A: - The core exchange cost for a set of RSR muffler for a 993 is $450 + freight

(freight cost to ship the muffler to you) The core exchange cost for a set of RSR muffler for the 993 twin turbo car is $550 + freight (freight cost to ship the muffler to you). You will also be responsible for cost of shipping your core muffler back to me.

A: - UPS(Ground) Insure the package for at least $499.
MOVED
A: - Yes

I will fully refund your paypal account once the muffler is received by me. Your only out of pocket expense will be the cost to ship the muffler back to me.

A: - That's the only other out of pocket risk you'll have for trying the RSR mufflers if you pay someone to install it.

I will not reimburse any labor charges or freight charges for the RSR muffler to be taken off the car. However I would be happy to make arrangements for someone in your area to meet up with you for a RSR muffler sound test prior to you placing your order to eliminate that risk. And if your are located in the Los Angeles area I would be glad to install the muffler for you free of charge.

A: - You can pay an additional $300 core charge for the 993 muffler and $500 for the 993 turbo mufflers.
A: - Yes, as long as they are original Porsche part that will fit on a stock muffler.
A: - I will gladly replace any muffler free of charge due to any defective welding on my part for the life time you own your 993.
A: - I originally came out with the RSR mufflers for my own 993,

it was friends that I made the RSRs for asked me to market this product. So at this moment I will not be doing anything else other than the 993 mufflers.

A: - Yes, that's why one of the questions I ask during the ordering process is the mileage on your 993.

I have a variety of different mileage cores on hand which I use to match up the mileage of your current muffler when I do the RSR muffler conversion. So that the RSR muffler you will be getting from me will have very similar mileage on it.

A: - No, the exhaust on the 993 does not provide any emission control devices.

It only muffles the exhaust sound.

My year 2000 emission test results

My 4 year old car with 36k miles passed all the test with flying colors.

 Reading2500 RPM test AllowableResultReadingIdle RPM test AllowableResults
HC-ppm4220PASS1220PASS
CO-%0.001.20PASS0.001.20PASS
RPM26152250-2750PASS813400-1250PASS
CO+CO2%14.46.0 minPASS14.36.0 minPASS
A: - Since 1998 the only returns from dissatisfied customers have been because the muffler was not loud enough.

Recently I have discovered that there are other individuals around the country who tried to modify stock mufflers to achieve the same result as the RSR muffler, but without any luck. Most of these modification were done with a MIG welder, which will not produce good quality welding with stainless material. Below is a picture that shows the difference in welding. (The below picture is a modified stock muffler done by someone else which I had to turn into a RSR muffler). All the welding for the RSR muffler is done on a TIG (Heliarc) welder, which is the only correct method to weld stainless steel, the results is self evident.

modified stock muffler done by someone else which I had to turn into a RSR muffler
A: - Strong

Below are two pictures that will show you how well the welds held up even when the muffler was crushed. This muffler came off a RSR muffler customer's 993 that was involved in an accident. The muffler was crushed on both sides. And not a single bead of the welding broke loose.

right muffler came off a RSR muffler involved in an accident. left muffler came off a RSR muffler involved in an accident.
A: - "Back purge" is a method used during welding where the opposite side of the welding area is also filled with argon to replace the oxygen.

The argon is kept at a constant flow rate to create an absolutely shielded environment for the melted metal on both sides. It is a time consuming method of welding, but I do back purge the RSR muffler while they are being welded. Below is a picture that shows the method that I use to back purge the mufflers. The tube is capped off with two rubber caps, one cap is fitted with a argon supply line and the flow rate is kept constant at 10-15 CFH, all the open seams of the mufflers that needs to be welded is taped up with masking tape, leaving only a small area opening waiting to be welded. I would peal back the masking tape one inch at a time as move forward with the welds.

back purged
A: - All the RSR muffler are welded back together with 316L stainless filler rod compared to 304 stainless that everyone else uses.

316L stainless is more expensive, but it is also a much higher grade of stainless steel. Although one might not eat off their muffler, but is good to know that food grade quality stainless steel were used. (Meaning that this is the grade of stainless steel required to be used on manufacturing of any food processing machines, and it is more corrosion resistance than the 304 stainless)

A: - Besides making the modification to make it sound better, I also go through the original factory muffler and make necessary repairs and touch up where the factory had missed.

Since the mufflers are welded up with automated welding machines by the muffler manufacturer there are a lot of "missed" welds on the muffler. I make a practice of making touch up to these "missed' spots during the RSR muffler making process.

From the below pictures you can see the picture on the left shows that the factory left out a 1/2" of seams on the welding. The picture on the right shows the repair I made to make it complete.

missing weld welded
A: - I can't guarantee what excuses our friendly local officer may want to use to pull us over...

I can't guarantee what excuses our friendly local officer may want to use to pull us over, but one thing I know for sure is that the RSR muffler sounds exact what our car should sound like from the factory.

A: - All the 993 mufflers are identical for the wide body and narrow body 993 cars

The only difference is in the exhaust tip off-set for the wide body cars, and the integration of the biscuits on the exhaust pipe of the muffler. On later 96+ 993s Porsche integrated the separate biscuit mating piece as one unit with the muffler, below is a picture that shows the difference. Either with or without the biscuit the fitment would be the same for all 993s. (none turbo model only)

Porsche have a patented design for connecting the mufflers pipes together, which in eliminated the use of any gaskets. The way the muffler is connected to the CAT. or the exhaust tip is through mating the pipes with a biscuit design and the flanges tights down the connection between them. Sometime in 1996 Porsche integrated the biscuit into their muffler pipes to save weight and cost.

biscuits
A:- Besides the brand and quality difference, they are dimensionally and functionally identical.

The Gillets cores integrated the biscuit piece in to the muffler itself as part of the pipe, and the Bischoff uses a separate biscuit system. (Biscuits are used in between the muffler tips to the muffler)

A:- Some people wanted the extra sound for their 993 but was afraid that they would loose points at a concour for having a modified muffler.

So the "RSR stealth mod" basically is a modification method that I used to cut open and weld up the RSR muffler at the original factory welded seam where it is visually very difficult to identify that the muffler was ever modified. The idea of "RSR stealth method" originally came from Gert in Belgium, this is the same exact method Gert uses to modify the RSR mufflers for all the European customers.

stealth modded two exhausts stealth modded close up
 

Twin Turbo Wing

car

My 1996 Porsche 993 Carrera Coupe (February 2002)

Rennlist

The best 993 discussion board on the internet today.

link to the rennlist forum

(site requires password to access)

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