Originally Posted by huntertec

Hi I modified my exhaust 2 years ago on my 2005 3.0d not by replacing the mufflers but simply removing the blanks, boring the correct size holes (to match the new tips) with a tungsten tip hole saw through the rear of the muffler important to leave the mesh screen inside the muffler so the tip can seat against it to be welded through the tip, make sure stainless tips are used,then cut off the existing tail pipes and use the left over plates from the new holes to weld over the tail pipe holes. I then cut out the blanks leaving 15mm gap around the new tips which looks very neat.There was an instant power increase and at idle only, sounds V8ish. This coupled with an ECU tune (REMAP) 200Kw & 600Nm.Yes there is still a soot issue but no worse than before in fact my BM is white and has stayed cleaner since the mod'. This way definetly works as I mentioned its been 2 years since the work was done ( alot cheeper to )