New 3" Exhaust Installation

[Jagdpanzer]

After many years running 2.5" Corsa exhaust decided it was time to upgrade the 427 to a larger 3" system. I talked to Billy Boat at BBE and their Fusion exhaust system with a bypass valve looked the way to go. Main requirement was it had to absolutely drone free which Billy promised it would be.
Finished the installation today. Took it for a drive and happy to report no drone and the sound is much deeper than the Corsa. Here are a few photos.
12521

12522

12523

12524


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[Ccmano]

Very nice and meticulous work as always. If you weren't all the way across the country I'd buy the Corsa from you.
H
:cheers:

[XfireZ51]

Phil,

Judging by the sparkling underbody, do u actually drive the car? 🤣🤣

[Jagdpanzer]

Hans,
Thank for the compliment.

Dom,
It's a driver.
Just carful to stay away from the mud puddles.


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[Paul Workman]

Very nice and meticulous work as always. If you weren't all the way across the country I'd buy the Corsa from you.
H
:cheers:

Hans... That's why God made POSTAGE STAMPS!!:razz:

[secondchance]

Now the 427 breathes as it should! :cheers:

[WARP TEN]

Phil, under what conditions do the bypass valves open? Are they vacuum operated or electric? Curious--Bob

[Jagdpanzer]

Driver decides if wants them open or closed.
Valves are vacuum actuated. System is controlled by remote key fob with on/off buttons. Vacuum signal is controlled by a solenoid valve. Valves are normally open so if the control system fails the valves automatically open.


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[G8nightman]

Looks Great are you selling your old corsa?


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[dredgeguy]

Outstanding Phil, can't wait to hear it at our next get together.

[Jagdpanzer]

Sorry, Corsa already spoken for.


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[HAWAIIZR-1]

Wow! If I ever buy an exhaust system, this is the one I want. Thanks for sharing Phil. It appears to be plug n play bolt on too.


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[tf95ZR1]

Beautiful!
So can you tell any performance differences?
Congratulations. So.... are you done now?
:)

[GOLDCYLON]

After many years running 2.5" Corsa exhaust decided it was time to upgrade the 427 to a larger 3" system. I talked to Billy Boat at BBE and their Fusion exhaust system with a bypass valve looked the way to go. Main requirement was it had to absolutely drone free which Billy promised it would be.
Finished the installation today. Took it for a drive and happy to report no drone and the sound is much deeper than the Corsa. Here are a few photos.
12521

12522

12523

12524


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

Very Clean Phil....always thought the Billy Boat fit the rear cut outs in the rear number Better than Corsa but went for the no drone option years ago

[Prez1967]

Looks fantastic!

Is this a new offering? I cant seem to find it on their site.

[Jagdpanzer]

BBE used their newest round design fusion mufflers. Billy said the round muffler provided better sound attenuation for its size than the previous oval version which enhanced the quiet/loud "split personality" of the overall system.


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[WARP TEN]

Driver decides if wants them open or closed.
Valves are vacuum actuated. System is controlled by remote key fob with on/off buttons. Vacuum signal is controlled by a solenoid valve. Valves are normally open so if the control system fails the valves automatically open.


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

Thanks Phil. A little bit like my setup on the '95 with a stock exhaust and Quick Time electric cutouts in that they are driver controlled with a switch in the cockpit, albeit electric not vacuum operated. --Bob

[RICKYRJ1]

Great Job as always, nothing but calculated performance & perfect execution in the pursuit of it :cheers:

[Top Toy]

If you look closely at the muffler photos, this is a radically different design from previous Fusions. The valved or "loud" side is a straight thru pipe. Bypasses the muffler, equivalent to exhaust cut-outs. Anxious to hear and see how it performs.

Sent from my SM-G975U1 using ZR-1 Net Registry mobile app (http://r.tapatalk.com/byo?rid=90383)

[rkreigh]

phils brake rotors are cleaner than my dinner plates (bigger too)


Congrats!! like to hear the beast and do another test ride with you soon. I need to contact you about a few finishing touches on LSV and the turbo z06 redo I'm working on. Thanks!

[Paul Workman]

phils brake rotors are cleaner than my dinner plates (bigger too)


The WHOLE car, top to bottom, inside n out is a jewel to behold!:thumbsup::thumbsup::thumbsup:

[WARP TEN]

The WHOLE car, top to bottom, inside n out is a jewel to behold!:thumbsup::thumbsup::thumbsup:

Agree with Paul--it's a beauty. As I said in another post, I truly think Phil sleeps under his car with a toothbrush and a rag.--Bob

[rush91]

That is a beautiful exhaust. Am I wrong or is your spare tire gone?? Reason I ask is because it looks as if the actuators would hit the spare tire carrier.....

[Jagdpanzer]

Spare tire & carrier were removed to make the install easier. Actuators clear the carrier ok.


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[Scrrem]

Very nice work Phil!!
Rich

[secondchance]

Very nice work Phil!!
Rich

I learned not to expect any less from Phil.

[mpiecyk]

Hi Paul,
Is it possible to post a sound clip of your new BBE by-pass valve exhaust system.
Thank You in Advance
Mike P.

[mpiecyk]

I'm sorry Phil, I did mean Phil.
Mike P.

[mpiecyk]

BBE- (Bill Boat Exhaust) Has engineered and manufactured a new Fusion type muffler system for the C-4 ZR-1 Corvettes. The part Number is FCOR-0011 you can find this system on his web site my questions are as follows to any members that has purchase this system.
1.How was the installation and fit.
2.Was the sound in either open or close position satisfying.
3.Drone if any please rate (1 thru 10) 10 being unacceptable.
Any info. would be greatly appreciated.
Thank You in Advance
Mike P.

[wfot]

the car is spectacular and spotless. and it does sound G O O D!
Phil was kind enough to fire it up for me at Carlisle
thanks Phil
John

[Jagdpanzer]

1.How was the installation and fit.
Installation went as usual for an aftermarket exhaust. After initial installation a number of tweaking adjustments were needed to get the tailpipe alignment right.
2.Was the sound in either open or close position satisfying.
In my opinion a deeper and more authoritative tone then the Corsa I had on before. Open tone is about the same as closed just louder.
3.Drone if any please rate (1 thru 10) 10 being unacceptable.
After 1500 miles have not experienced any drone whatsoever. Will record some sound clips next time I have the car out.

[XfireZ51]

Phil,

I don?t have a Fusion setup, but mine is similar in use in that it incorporates the NPP Z06 valves welded onto 3? ID DynoMax UltraFlows(thx Al). I use a console switch to activate vacuum for open and closing of valves. I find that I regularly need to tighten the hanger nut on my driver?s side muffler. I know u are putting down more torque w ur 427 than my modded 5.7L. Have u experienced anything like that, and if not what been ur solution for keeping the hangers tight?

[mpiecyk]

Phil,
Thanks for the feedback its greatly appreciated.
Mike P.

[Jagdpanzer]

Dom,
Not a fan of rigid exhaust pipes. Installed flex joints just behind the cats to reduce the bending forces on the down stream system.
13509


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[XfireZ51]

Thanks Phil. Always innovative. I don?t have cats in mine. How much do u think the addition of cats contributes to the exhaust note u currently have?

[Jagdpanzer]

I didn't do any before and after comparison testing so not sure if they have any influence on the tone. However, I know from previous experience they slightly attenuate exhaust sound level emitted from the tail pipes.


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[Corvette95]

What headers and cats are you running? I am contemplating a new exhaust if I decide to replace the motor mounts on my 90. Also, what is the vacuum source for the exhaust valve?

[Jagdpanzer]

Stainless Works long tube headers.
Global Emissions Systems (GESI) 85030 cats.
Used the vacuum fitting on the left side of the plenum that was previously used for secondary port actuation.


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[XfireZ51]

I used the vacuum line for the charcoal canister.

[Corvette95]

What set of new header bolts are you using? I have seen 3 different types mentioned on other threads, is there an issue of bolt material going into aluminum (galvanic corrosion) ? Also, have many bolts did you put back in each header?

[Ccmano]

What set of new header bolts are you using? I have seen 3 different types mentioned on other threads, is there an issue of bolt material going into aluminum (galvanic corrosion) ? Also, have many bolts did you put back in each header?

I've used these several times with good results and zero backing out.
H
:cheers:

https://farm66.staticflickr.com/65535/50662730687_3854566022_c.jpg (https://flic.kr/p/2kbTJLF)

[Corvette95]

Question: ( I also posted this on our FB page) I do not have the funds to buy the catback system that I want so I am going to have to put the OBX headers on and attach to my Flowmaster catback that I have on it now), I have no experience with exhaust other than bolting on, the Flowmaster is designed to attach to the stock manifolds, what do I need to do to connect the Flowmasters to the OBX with the flange to bolt to? What do I need and I know I read it on a search but can't find it now, what clamps do I need for the OBX's instead of the ones that come with the OBX's ? Also, can't get it to the exhaust shop as the transmission is out for service plus I need to stop the cash burn . Thanks

[Corvette95]

Look at my exhaust and please tell me if this is a stock set up for a 90 or if the passenger side has been modified. Thanks

[Jagdpanzer]

Finalized my 3" BBE Fusion exhaust installation by adding a pair of Vibrant 1795 straight-through perforated core resonators. Adding these was planned all along. Reduced the overall exhaust noise level somewhat and no drone at any road speed.
13969

13970


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[Corvette95]

Finalized my 3" BBE Fusion exhaust installation by adding a pair of Vibrant 1795 straight-through perforated core resonators. Adding these was planned all along. Reduced the overall exhaust noise level somewhat and no drone at any road speed.
13969

13970


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

Very nice! My dream exhaust! :thumbsup:

[secondchance]

Finalized my 3" BBE Fusion exhaust installation by adding a pair of Vibrant 1795 straight-through perforated core resonators. Adding these was planned all along. Reduced the overall exhaust noise level somewhat and no drone at any road speed.
13969

13970


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

I?ll vouch for that! Sounded awesome!:cheers:
Thanks for the ride!

[XfireZ51]

A short video clip
https://hosting.photobucket.com/images/gg333/pwasinger/ZR_1_BBE_Fusion_Exhaust.mp4

Phil,

Not playing for me.

[Jagdpanzer]

A short video clip
https://youtu.be/fz9544XtQDY


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[mpiecyk]

Thanks Phil sounds like a must for my "Z".
Mike P.

[HAWAIIZR-1]

Damn Phil, I wish you wouldn?t have shared this. I know it won?t sound as good on my stock motor, but now I really want one!! [emoji847]🤙🏼


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[secondchance]

Damn Phil, I wish you wouldn?t have shared this. I know it won?t sound as good on my stock motor, but now I really want one!! [emoji847]🤙🏼


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

Craig,

Good to see you doing well.
I?m not so sure you want 3? exhaust on a stock LT5. Might slow the exhaust too much.

[HAWAIIZR-1]

Craig,



Good to see you doing well.

I?m not so sure you want 3? exhaust on a stock LT5. Might slow the exhaust too much.



Hey Yun! Thanks for your thoughts. I guess I had second gen B&B before and never thought about that and will consider. I will see how it is after I install the ported top end I have and shorty headers. I have already removed choke points from the stock exhaust with resonator replaced with Magnaflow Tru-X muffler and mufflers with Dynomax VT mufflers. But like you said the B&B Fusion might not have enough back pressure for a stock motor. Since I see that Corsa makes the most power (just don?t like the sound and concept) and 2 1/2 in pipes compared to stock 2.75 in pipes;at least the bends in the stock pipes are pretty nice, despite not full mandrel bends. Just gotta get home to the Z first. 🤙🏼


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[XfireZ51]

Phil,

Similar sound to Z06 NPP w 3? pipe and DynoMax Ultraflows.
Cammed but not a 427.

Closed


https://youtu.be/WJ71UnFyZzs


Open

https://youtu.be/muNNY-NQtGc

[HAWAIIZR-1]

Phil,



Similar sound to Z06 NPP w 3? pipe and DynoMax Ultraflows.

Cammed but not a 427.



Closed





https://youtu.be/WJ71UnFyZzs





Open



https://youtu.be/muNNY-NQtGc



That sounds nice too Dom!! The BLUF is cammed LT5s sound good!! 🤙🏼[emoji38]


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[Corvette95]

Well I am completely inspired by Phil's work of art. I have decided to in addition to OBX headers, cutting my Flowmaster (assuming Eric doesn't buy it today), keeping front end where mounting tabs are, running flex tube to the stainless rear small pipe to fabbed tubing to the two Vibrant 795 resonators, then connecting all to the flowmaster mufflers that sound really good. Once it is all adjusted and fabbed, I will have it all ceramic coated headers are being coating right now). I am hoping for good power and no drone, will get another chip tune. Stay tuned. My personal deadline is December 31st for my finish date. BTW I have access to all my oil pan bolts, I tighten them all, would any benefit come from removing all the bolts and resealing them or even more extreme drop the pan and reseal, I am not getting much of a leak and that was before tightening all bolts.

[1991 Corvette ZR-1]

I was curious on this if anyone may have figured a way to automate the valve opening process or was it strictly a manual only option through the fob with this? I?ve always enjoyed the civility of the exhaust and how it just rolls in and out of the louder valved side on those types of systems just off throttle usage alone.. I suppose those systems use a complex approach that measures rpm output/vacuum signal to open valves.

I?m running a Corsa with OBX headers and was curious if the B&B fusion would be worth the switch.

[Jagdpanzer]

On my system on/off control is either by the key fob or when you go full throttle the manifold pressure goes to nearly atmosphere which allows the normally open vacuum actuated exhaust valves open automatically. They start closing again when the vacuum returns.
Guess I could put a check valve in the vacuum supply line to keep the valves closed when going full throttle but kind of like it the way it is. Never know when full power might be needed. Don't want to be fumbling with the key fob at that particular moment.


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[1991 Corvette ZR-1]

On my system on/off control is either by the key fob or when you go full throttle the manifold pressure goes to nearly atmosphere which allows the normally open vacuum actuated exhaust valves open automatically. They start closing again when the vacuum returns.
Guess I could put a check valve in the vacuum supply line to keep the valves closed when going full throttle but kind of like it the way it is. Never know when full power might be needed. Don't want to be fumbling with the key fob at that particular moment.


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

That is what I meant, sorry Jag. My brain clicked off thinking about the system when you mentioned a fob to control it manually. For whatever reason, I thought the only way to control the valves was manually. Yes, the valves opening on their own as you get on the throttle was exactly what I wanted with the system. Based on your experience with it versus a system like the Corsa, was it worth the move?

Mine is nowhere near yours, just top end porting with headers straight into Corsa. I love the Corsa for the no drone, but I also like the sound the fusion makes and the X pipe design in the full cat back system is a nice touch. Trying to decide if I want to send my top end out for refinish or get the fusion instead.

Guess these are good problems to have.

[Top Toy]

FWIW, I specified my Fusions with no valves. Love the sound at all rpm's and engine loads. No drone.

[XfireZ51]

I decided on putting in manual switch on my NPPs. Did not like valves opening on their own based on vacuum. and yes I have a check valve w a vacuum solenoid.
I believe former member mike100 had nicroswitch setup to control what vacuum and rom valves would open.

[Marc Haibeck]

It's easy to control the valves with an RPM switch. Use Summit Racing PN SUM-830453. $50. Connect it to the B&B vacuum solenoid. Then you can set it to automatically open the valves at, let's say 4000 RPM.

Since the vacuum solenoid valve is opened to close the exhaust valves, the RPM switch control signal would need to be inverted by a relay.