Exhaust Backpressure Study

Replacing the stock production exhaust system with a low-restriction, free-flow one is usually one of the first modifications made to any vehicle in the name of performance. We all know they're louder, but how much performance do they really add? We've all seen supposed dyno tests, usually run by the exhaust manufacturer's themselves on their own dyno, indicating vast power gains, and psychologically, we always equate a healthy exhaust rumble with increased power in the seat of the pants, but how much power are we really gaining? To find out, we're running a simple backpressure study, and our results will be posted here as they come. Admittedly this study is not totally scientific as there are many uncontrolled variables, but it should be sufficient to provide a rough estimate.

It is generally accepted by automotive engineers that for every inch of Hg of backpressure (that's Mercury - inches of Hg is a unit for measuring pressure) approximately 1-2 HP is lost depending on the displacement and efficiency of the engine, the combustion chamber design, etc. Our sources indicated that in the case of the L67 3800SC, 1HP per inch of Hg is reasonable.

1 inch Hg backpressure = 1 HP lost

For reference, we have the following conversions factors:

1 ATM = 14.7 PSI = 76 cm of Hg = 29.921 inches of Hg = 1.013 bar

Our test vehicle is a '97 Buick Regal GS with 3800SC engine transversely mounted. It's exhaust system consists of a cast iron exhaust manifold on the left side of the engine which connects into a tuned tubular header on the right side, both banks connected to a single downpipe into a catalyst. The output of the catalyst runs into a resonator and then into a single muffler; all pipes are 2.25 inch. The exhaust system is very similar in the Pontiac GTP, the differences being that the GTP splits into 2 mufflers after the resonator. Our sources indicate that the GTP system results in approximately 3 in Hg less backpressure than the Regal, hence there is 3 less horsepower loss.

To measure system backpressure, a sample tube was mounted before the catalyst into the downtube as shown in this close-up.

A flexible hose is run from the sample tube and attached to a pressure
gauge inside the car for monitoring.

This is the gauge reading at max pressure. Notice RPM on the tach. We apologize for the photo - the shutter speed wasn't high enough. (We fired the photographer. <grin>)

We first ran the test with the complete full factory exhaust, and next dropped the entire system from the catalyst back. Notice again the sample tube visible in this photo.

The final test was run with the muffler removed. Only the catalyst, resonator, and the majority of 2.25 tubing up to the muffler remained.

Next we took a look at the restrictive U bend that houses the post O2 sensor. It's function is to protect the O2 sensor from damage by positioning it straight up.

This restrictive U bend is completely removed, and replaced with a straight 3" piece. (Note this 3" piece is not the actual replacement pipe - it's just a scrap piece for the photo.)

This U bent tube is replaced by this straight 3" pipe. The O2 sensor is mounted to the side - less protected, but it'll be OK unless you go off-roading as we recently did!

Here's a better photo of the replacement pipe

Results & Conclusions

We ran three tests, observing three runs with each configuration and averaging the three. Peak backpressure occurred near the engine RPM redline of 5700-6000 rpm, at a max boost of approximately 7-8 psi. We took all our readings at WOT immediately before the 1-2 shift. Although we performed our tests on a Buick Regal GS, we predict a GTP will have similar results, taking into account the 3 in Hg difference. We realize our tests are not totally scientific, and they were not meant to be. Our goal is to obtain a ballpark estimate which, as the saying goes, is "good enough for government work." [Before you government employees start flaming us - one of our associates worked for the US Army Corps of Engineers for several years, so we know how it is. 8^) ]

1. Full factory exhaust system of catalyst, resonator & muffler: 28-30 in Hg = 28-30HP lost [system is whisper quiet]

2. Only catalyst in place, no resonator or muffler after the cat: 13-14 in Hg = 13-14HP lost, thus approximately 14-17 HP gained over stock full exhaust [system is unbearably loud and shakes the entire car, conversation is impossible]

3. No muffler, just resonator, catalyst & tubing 20 in Hg = 20HP lost, thus approximately 10HP gained over stock full exhaust [system is bearable, but has some bad resonances and drones at particular RPMs.]

4. "U" pipe replaced with straight 3" pipe Testing to be determined.

The catalyst was never removed as we were only interested in achieving an optimal cat-back system. We can see from our results that the muffler is costing approximately 10HP loss while the resonator accounts for a 6HP drop, with everything from catalyst to the engine costing 14-15HP.

Therefore, it's evident that at best, a free-flow system will gain perhaps 10HP - and that's for a noisy system, while one which controls irritating resonances and drones better would probably gain less than that. Therefore, a 5-7HP gain from a cat-back exhaust system is probably in the ballpark for achievable gains.

Will removing the catalyst help? Definitely, but that's illegal for street use and probably more importantly to some folks out there, it sets an OBDII Malf code. Replacing the factory catalyst with a high-flow unit will not result in a significant increase either, as those "high-flow" units outflow a production unit by a couple of inches of Hg at best. In fact, our sources indicate that the catalyst on these cars are actually one of the least restrictive available. With a FWD platform, we're stuck with uneven header lengths due to the transverse mounted engine, limiting one's ability to truly optimize the header design. Therefore, it is probably more fruitful and definitely more cost effective to examine the situation after the catalyst.

The difficulty in designing an effective exhaust system is in minimizing backpressure while achieving a desirable exhaust tone with minimal resonances and drones. It has been suggested that replacing both the resonator and muffler with a single large staight-thru muffler (with dual outlets for the GTP) may be the best solution.

All exhaust work courtesy of Affordable Muffler of Frankfort, Indiana. 765-654-9598

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