+T... 2.5 or 3inch Exhaust?

I really don't think there'd be any clearance issues with a 3" exhaust, unless for some reason you were going over axle with it.

Dauntless

I really don't think there'd be any clearance issues with a 3" exhaust, unless for some reason you were going over axle with it.

The 2.5 inch under-axle OE Volvo pipe has a dent in it for clearance, so if you go under axle with a 3-inch pipe it will be even worse clearance or larger dent than OE 2.5 inch pipe, unless you want to sacrifice ground clearance. FWIW...here’s a pic of the dent on the OE turbo 2.5 inch under-axle pipe

3" over axle is entirely possible with no clearance issues, it just takes a bit more time and hence $ if you can't do it yourself. I built one for my 242. By built I mean I took a 3" exhaust off a car I had and ended up pretty much redoing the whole thing because it hung to low and at full suspension compression interfered with the torque rod bracket on the axle.

Back to the question at hand, 3" future proofs your build. Your not going to save much $ by only going a 2.5" which might not meet your future needs.

@Dauntless that looks good and looks like plenty of clearance. I assume the reason Volvo put the dent in the top of the pipe was to allow a bit of extra ground clearance on a stock ride height car without having the axle hit the pipe too often when the suspension goes into hang. Car manufacturers can’t get away with as much stuff as we do on our own cars as we’re willing to put up with a few drawbacks to achieve an end result. On my car, 2.5 inch should be sufficient since I don’t plan to run more than standard boost. As @VolvoHordz said if you have the capability to build it yourself, then you can do it properly. I just don’t like the idea of paying an exhaust shop $1000 for some f**ked-up mess...that’s why I bought the OE Volvo 2.5 inch system. There’s also a Simons sport Turbo exhaust system available that could be a good option for somebody looking for a bolt-on system, however the shipping on that system is pretty expensive.

With a 3" downpipe and 2.5" back from there with straight through mufflers, you should see minimal restriction running 15psi on a small turbo like a 15G. I think that's worth considering, as a stock turbo on wastegate pressure makes for a pretty dull/slow car.

It's important to find an exhaust shop that will do what you want, though.

Seems pretty good price if you can get it delivered for that. You can be the guinea pig and let us know! :)

Ipd do a 2.5" system off the shelf

Exhausts vary wildly in prices depending on the shop and how much they want the job. If $600 for a cat-back system seems like good value, then keep talking to more shops.

Even in over priced Canberra, I can get a custom system for less than that.

Have it open at like 5psi with a boost tee, straight after the 3" cat. Retain stock exhaust. it's what I'd do if I had my time again - no drone, no clearance issues, only noisy when it actually needs to be.

carnut222

gavinh

Ipd do a 2.5" system off the shelf

But postage and exchange rate...YIKES! IIRC the Volvo GCP 240 Turbo system is cheaper and genuine Volvo...I’ve heard some of the ipd systems may not be great...but that’s anecdotal. They do have some nice-looking SS systems...most of theirs say non-turbo though, not sure why??

Yeah I had one on a N/A opened it up, was probably the fastest stock 240 I have owned (85 kjet). At the time we had a good exchange rate and was way cheaper than what the local shops in WA could even touch. There were a couple of fitments issues but was cheap and chearfull

Just for some food for thought, I'll add a story:

Back in '05 when I first got my 760T, it was totally stock apart from a boost gauge, still auto. The exhaust was a stock 2.25" dump pipe, into an NA 2" system, and for some reason a 1.75" tailpipe. The turbo used to glow orange easily when it had this exhaust.

I put it on a dyno to get a measurement of what I was starting with, a whopping 77kw, with 7psi boost.

I then unbolted the exhaust at the flange at the end of the stock dump pipe, and did another run, this time it made 100kw!

I then got a 3" turbo back system made up with no cat and two mufflers. The boost went up to 8psi without me changing anything, and it dyno'd at 96kw.

With a few other mods and 12psi it eventually made 163kw, so I consider a full 3" system a worthwhile supporting mod.

Love it! You are onto a whiner there.

Is it a 3" over axle system? No dump pipe?

Have you fitted this yet? Im really keen to do the same thing. Value for money seems great.