Hi guys,

I recently ordered an EP1 that should arrive in a few weeks. In the meantime, I've been debating on whether I should do the install with a buddy of mine who works a lot on cars (albiet never on Porsches). I've emailed some of the moderators on here for advice and I appreciate the feedback. Just wanted to find out how many of you have actually done an exhaust install yourselves, and if you did, how many of you had the turbo studs break (or run into any other problems for that matter)? I've heard if that happens it's a PIA! What would you do in that case? Take off the turbos or are there commerically available products (like Bolt Out) that would work? I bought supposedly one of the best penetrating oils (AeroKroil) and I've been told that if you soak all the nuts well (haha, no joke intended ), it should loosen them up and the studs should not break. I've been quoted anywhere as low as $400 up to $650 for install (which I don't think includes if THEY break the studs and you never know what some of these indy shops will charge when the work is done). What's a fair price? So just wanted to get some opinions and advice.

I should also clarify that it's not the money for the install that keeps me from wanting to take it to a shop. It's the PIA of having to drive the exhaust in another car separately to the shop, then bring my car in, arrange for a ride back to work, etc. Just seems so much more convenient to do it at home, plus I'm sure I'll be a lot more careful and meticulous.

Thanks!

 

I'm in the same position as you. There's always some degree of pride (whether it is a PITA or not) in being able to do a DIY on any car upgrade but I have opted instead to have a shop install the exhaust.

You can also have the company ship the exhaust to the shop directly so you don't have to carry it to the shop. Although if you wanted to keep the OEM exhaust, you may still have to make a second trip to the shop. Doubt either will fit in the TT, otherwise risk damaging the leather.

Hope this helps.

 

Use a shop. Its a messy and knuckle thrashing job.

 

Do it yourself. I did - I would consider myself generally unskilled at most car related mechanical things and the tools and guidance provided by Stef made this a straightforward and simple process. It took me and a friend just under 7 hours to do it.

 

Did you have any studs break? Did you have to take off the turbos? Intercoolers?

Thanks

 

We always recommend dealer installation on our exhaust systems. Just for peace of mind with experience Porsche technicians. You wouldn't want any rattling issues or something along those lines.

 

it all depends on your skills. Im told the EP is a pretty tight fit.

 

EP1 - Is simple to install... It is tight on the upper turbo nuts to take off and put on but nothing complex - just a slow process. Turning a nut 1/4" at a time. Installing an exhaust is trivially easy. I cant imagine why you'd need a "technician" for such a straightforward install. Its like needing a "technician" to install a license plate.

Stefs directions are simple to follow. Again - 7 hours with a buddy should be fine to get it done. That's while eating pizza, drinking a few beers and having friends over to poke fun at you on saving $500 install bill on a $200k car.

I learned much from doing this.

Spatia

 

Turbos and Intercoolers do not need to come off.

No stud breaks either.

 

The job is straightforward. It also becomes MUCH easier if you take off the ICs, which is not difficult or time-consuming. Access to the top two studs on the turbos and the O2 sensors gets a whole lot better with the IC's off and the heat shield folded up. Highly recommended.

As for stud breakage, nothing will take them out except a machine shop. I drilled out the stud to within 1/64 of an inch of the stud size and thought I was home free. Nope. My tap then broke off without making any progress toward chasing out the minor amount of stud metal left in the threads--and I was being careful. The metal of the stud is one with the flange as far as I can tell--permanently bonded.

I soaked with PB Blaster for a week before, and I successfully removed the nuts. It was on re-tightening with the new cats that the stud broke--at less than the specified torque. They are just brittle, and sometimes it doesn't matter how careful you are. I had to remove the turbo after trying every method available to me over two weeks.

You are correct to think that installation costs probably don't include the cost of removing a turbo and taking to a machine shop. My Porsche service manager confirmed that when I was telling him my story. For any given shop, I would settle the issue up front.

I would still do it again myself.

LP

 

Thanks for sharing. Wow! That sounds miserable! Looks like I'll be taking it to a shop!

 

I've mounted 3 exhausts on my car so far. Milltek, EB Werks and now the GMG. Not too hard, but while you're in there, it's a good idea to replace the studs, they're not terribly expensive. The nuts are designed for one use as well. I just double nutted them to get the old ones off and the new ones on, and they came right out.

You'll need 8 of each:

90008105901 - stud
99908405202 - nut

I got lucky and each of the exhausts I did were not really a problem with the bumper on (but the milltek really should have removed the bumper... what a bear!)

The trick I used was a shallow swivel socket.
This allows you to get at the nuts from behind the car. Much easier than trying to thread a wrench up in. (not possible on the stock exhaust, and it will depend on how big your cats are if it will work on the aftermarket.)

 

It is not a difficult job and Stef provides a little custom wrench to aid in doing the job. I also would second the purchase of a small shallow socket, combined with swivel extension and various length extensions and a short handled driver and its a piece of cake (the second time).

 

If its over 2 hrs I dont want any part of it! Anthony at Stuttgart took better care of my car than I could armed with tools under the Turbo. With 3 kids 7 hrs in a row are a rarity for me!