2015 Mustang EcoBoost exhaust Y-pipe welding

Enhance Your EcoBoost Exhaust! Cat-Back Development, Part 2: Sound Testing and Second Prototype

First Prototype: Sound

We’re starting this article with a recap of Part 1 of this series, which highlighted our first prototype for the 2015 Mustang EcoBoost exhaust design. If you recall, this design featured a midmuffler as well as two rear mufflers.

We promised a sound clip of our first design, so check it out below!

As you can hear, this setup is not quite what we are looking for. Although our mufflers are more free-flowing compared to the stock units, the sound of the EcoBoost is still stifled quite a bit. In fact, actual noise increases over the stock exhaust setup are minimal and nearly unidentifiable.

We needed to make some modifications to create a more prominent sound. Back to the drawing board!

Prototype 2 Plans

This project is turning out to be quite an experimental process. We had planned to try numerous different configurations until we attain an optimal sound. Stick with us during the process to see what changes in design make the most impact on the tone and volume of our EcoBoost.

Our next plan is to eliminate the midmuffler. By removing it we should see a weight decrease as well as a louder exhaust. We are sticking with the same rear muffler in order to change just one variable at a time.

Prototype Fabrication

Our first task is to create a Y-section to replace the existing midmuffler. We began cutting pipe to the correct dimensions to prepare for welding.

2015 Mustang EcoBoost exhaust Y-pipe fabrication
2015 Mustang EcoBoost exhaust Y-pipe fabrication
2015 Mustang EcoBoost exhaust Y-pipe fabrication
2015 Mustang EcoBoost exhaust Y-pipe fabrication

A bit of welding ensures that exhaust leaks will not have an impact on our testing.

2015 Mustang EcoBoost exhaust Y-pipe welding
2015 Mustang EcoBoost exhaust Y-pipe welding

Once complete we had our second prototype ready for some additional sound testing! Check it out!

Mustang EcoBoost exhaust Y-pipe installed
Mustang EcoBoost exhaust Y-pipe installed
Mishimoto second prototype for the Mustang EcoBoost exhaust
Mishimoto second prototype for the Mustang EcoBoost exhaust

Prototype 3 Fabrication

Another one already? Yes, we are making a third prototype. This one will be much easier. Our plan is to try out a couple different muffler styles to evaluate the sound produced. Our third prototype is similar to the second, yet features a round rear muffler. This will impact sound in terms of both volume and tone.

Here is the muffler we intend to test with our 2015 Mustang EcoBoost exhaust!

Third prototype muffler
Third prototype muffler

First we mocked up our plans for the pipe route. The angle would need to differ for this muffler due to a longer length.

Mishimoto third prototype for the 2015 Mustang exhaust mockup
Mishimoto third prototype for the 2015 Mustang exhaust mockup

We added a few tacks to ensure that these components stay in place during our initial placement.

2015 Mustang EcoBoost Exhaust, prototype fabrication
2015 Mustang EcoBoost Exhaust, prototype fabrication

Next we made adjustments to the mounting locations and pipe length to achieve our desired placement.

Mishimoto third prototype for the Mustang EcoBoost exhaust mockup
Mishimoto third prototype for the Mustang EcoBoost exhaust mockup

Once we had our dimensions and angles correct, we assembled and installed the third prototype exhaust. Check out a few shots showing the pipe routes.

Mishimoto third prototype for the Mustang EcoBoost exhaust mockup
Mishimoto third prototype for the Mustang EcoBoost exhaust mockup
Mishimoto third prototype for the 2015 Mustang exhaust mockup
Mishimoto third prototype for the 2015 Mustang exhaust mockup

We then fully welded the pipe assembly to provide leak-free operation during our upcoming 2015 Mustang EcoBoost exhaust testing.

Final pipe welding
Final pipe welding

You will notice that the end of our mufflers do not quite reach the outlets of the bumper. For testing purposes, we needed to put together a quick set of tips to prevent the hot exhaust from melting the bumper.

Mishimoto 2015 Mustang EcoBoost exhaust fully installed
Mishimoto 2015 Mustang EcoBoost exhaust fully installed

Keep in mind that these muffler tips were used purely for testing. We will be taking a close look at exhaust tip design options to select something aesthetically pleasing for the rear bumper profile of the Mustang.

Below is a summary of our prototype designs thus far.

Chart

Prototype 2 & 3 Sound Testing

Now we just need to hear how these new prototypes sound! Check back next time for sound clips with both of these mufflers setups.

Thanks for reading!

-John

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