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Old Oct 19th, 2007, 06:07 PM
Mini "S" BRG
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Maganflow Install on Cooper "S Now Quiet!

I saw a very good deal on the Magna Flow Exhaust for the Cooper "S" for $539.00 "Delivered"! I looked around to see how loud / Quiet it was but could not see anything that made me know it was loud and Buzzy inside so I bought it!


Nice Quality and eas Install then I fired it up! Sounded like the Asian Cars with the 4 inch Open Mufflers or like a loud motorcycle! Also between 2,700 and 3,300 the Buzz / Humm inside the car bothered me and my wife (Who owns and drives the car daily! We have an Older 911 Porsche with 2 into 2 muffler and sort of loud but a good sound and no Buzz inside and we both own Motorcycles so we are no Wussy to noise!

I called Magnaflow and they suggested we put in another Resonator The the car will have "4" Mufflers! I got the 2.5 inch tube 14 inch long muffler Body and 20 inch over all length. The Mid Pipe is 21.5 inches long so I cut about 7 inches off the tube and had it welded. I should have cut 1 inch off the Muffler tube then welded it to give me more room to move the Muffler around.

I installed this part and Immediately the car was better! Just a little louder than Stock when starting up (Like the Original Muffler that had started rusting out where the main tube inters the Right Muffler) and only when on the gas was it loud but not offensive. I take it for a test drive and not bad so far. We drive it to church and hear some Frequency noise between 2,600 and 3,300 (65 to 80 MPH) but not too bad. We then washed the car and heard a few scraps under the car and a few miles later the car is Loud as ever! I looked under the car and saw nothing wrong.

Sunday I take everything apart and find that to make sue I can get it apart I had Anti-Seize in the t main bolts that hold the system to the header and 1 Bolt had backed off and left the car! (The noise we heard on the road)

I also decided to Use Header wrap to really get rid of the last bit of inside noise and found that it did not help in noise but did seem to increase the Power.

Looking under the car, this part sits lower than I would like (We have yet to scrape anything) so I bought a 1.25 inch wide 26 inch long piece of Strap Steel and 4 large hose clamps. I am going to bend this piece of Strap so it will clamp to the tube in front and behind the Resonator and act like a Skid Plate. The Resonator is 4 inch Diameter which makes it 3/4 inch lower than the regular pipe!

With this modification $60 delivered for the Resonator and $15 to Weld it, I am NOW 100% happy with the LOOKS, SOUND and Performance of the Magna Flow exhaust system for my 2003 Cooper "S"! Not quite a Stock replacement but Liveable!
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Old Oct 23rd, 2007, 09:40 PM
Mini "S" BRG
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Had a problem with the Edit!
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Old Oct 23rd, 2007, 09:44 PM
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Quiet outside! Still TOO Much Drooning and Resonance inside between 2,700 and 3,300 Rpms for my wife and I do not care for it either! I just bought a Glass Pack from Summit Racing Part number SUM -630805 for $21.05 It is 18 inches long with 2.50 Inlet and outlet with a 2.50 inch core. I am hoping that thus us a Louvered Core to take out more noise than the Straight through drilled tubing of the Magnaflow. From the outside the Magna Flow looks and sounds great! I just cannot get rid of this last noise problem!

If this does not work, then I will get a Flo-Pro Glass Pack Muffler that has a 15 inch body and is 20 inches long (overall) that has a 2.25 core with spiral louvers and weld the 2.50 inlet and outlet Stainless ends on it from the remaining center tube from the original system!

I know reducing the internal size will reduce the noise but at what cost in performance?

Will the exhaust temp increase too much?

All I know at this point is I still have 2 more tries to get this right inside before I run out of Options.

The good news is, I am still ahead of the game Cost wise. Spent $539 Delivered for the full MagnaFlow system for the 03 MCS and $63 for the 4th Magna Flow Resonator and $15 for the welding, Add to that $31 delivered for the Summit Racing Glass Pack and I am at $649 total! Still under the average price for the entire system and the BETTER News is, the car is running like a Scalded Rabbit! Even with Traction ON, the tires are trying to spin up all of the way to redline in 1st and second Gear and some what scary to drive with WOT in any gear!.

SO Far I love how it looks on and under the car! I Love the performance and I like the sound "Outside" the car with the 2nd Resonator on the car! I sure would not buy one without the second Resonator because in and out it is waay too loud! My Hope is that before I have spent $700 USD I get this right and we all can live happy.

"Anyone here have a DINAN Exhaust on their car? A friend of mine is looking into that 1 muffler special. Is it as loud as a Borla or other system?
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Old Oct 24th, 2007, 01:58 AM
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Give this article a read Intake & Exhaust Systems - Tech - Sport Compact Car Magazine .

I’m in the process of modifying my OEM exhaust to accept a custom header and will be trying this type of resonator Flowmaster Hushpower II Resonators: FLO-12412400 - summitracing.com . It will be some time before I can provide any noise feedback on this product, but I can say the design is quite unique and very robustly built; the space available for length, limited choices to only 12inch options (Flowmaster makes more sizes), for the first stage. If this doesn’t work out then I’ll try one of the Magnaflow straight through resonators/mufflers. I looked at a glasspack with louvers, an exhaust specialist told me to only use one as a last resort, he said it wouldn’t do much for sound levels and would be only marginal at reducing a bitter rpm specific resonance I want to dampen. For whatever it’s worth, the Flowmaster Hushpower II weighs a whole lot more than a similar sized glasspack.
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Old Oct 25th, 2007, 04:50 PM
Mini "S" BRG
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Great Post! Exactly what I have learned so far!
Summit Glasspack Mufflers: SUM-630805 - summitracing.com
This is what I bought to see if I can get rid of that last Droning sound! I do not know if the core is drilled tube or louvered. With your post I am glad I did not get the Flo-Pro which has a Louvered Spiral design now!

the 4 inch diameter is Very close to the Max you will want to put under your car! The 4 inch leaves about 1/2 inch clearance all of the way around and 5 inch diameter may touch the Heat Shield.
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Old Oct 26th, 2007, 02:50 AM
Trailer Trash
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When you have an opportunity, please take a photo and share. I would like to see the Magnaflow resonator section behind the central bracket before you swap it out.
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Old Nov 17th, 2007, 02:02 AM
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This short resonator is highly effective.


The elevated noise level that came with the addition of my custom header has been greatly reduced. A 2,300 rpm buzz hasn’t been removed entirely but it is far less intrusive and the duration has been shortened as well.

A low profile design allows the resonator to stay up and out of the way.

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