Looking for an exhaust for 2004 T5 AWD

[Siward]

Hello all.

My garage tells me that the exhaust on the old wagon is on its way out- its blowing at the front and either needs a new front section or some way of repairing it (he's already welded it once) and also the back box is just rotting away too. I'm told that the Cat is OK it is just all the pipework around it that is failing.

My garage man says he is finding it impossible to source the correct system and indeed the internet isn't overly helpful either.

So really I need a complete exhaust system. I don't really want to spend on a stainless system or 'performance upgrades' I just want a straightforward, as stock, system maybe even in mild steel (given that I'm not going to keep the car for ever perhaps a couple more years).

Garage man suggests finding a local exhaust specialist and indeed there are some (Derby/Alfreton area) but they all seem to offer very nice but- for my needs- over-specced systems.

So what are my options? Can an 'as stock' system be obtained at a reasonable price? If so, where!

[Brimfull]

A custom made stainless system from an exhaust fabricator will not cost that much money maybe in the region of £300+ . You choose the tail pipe design and it does not have to be ear piercing loud.

Makes more sense to buy stainless steel over anything else.

[Siward]

£300 would surely be for a so called 'Cat back' system, i.e. only the rear half of the whole assembly, no?

[iainmd]

I had the Jetex stainless system on my S40 T5 and loved it. No drone at cruising speeds but a nicer burble at idle and throatier under acceleration without being brash. Only thing I would say is if you don't have the sport bodykit or an R-Design the tailpipes will look like jet pipes and protrude too far.

The BSR or Ferrita systems are nigh-on identical to the Jetex. The Jetex was about £440 when I bought it in 2006 and is now £505.

[domhart10]

Yeh it will be difficult to source an oem exhaust system, and also quite expensive.

It might be an idea to pop along to a custom exhaust garage and have one made to your spec (Yes they will probably try offer a more performance orientated exhaust but its really up to you what you want). That way you can decide what system and material you want.

[Welton]

I fear the same fate coming to me, pipe entry to the main rear box is very 'soft' now and has a little hole which I keep patching with GunGum so not ideal.

Last time I enquired the standard systems were not replicated by any aftermarket exhaust manufacturers as there was zero demand for them. The Volvo exhaust was stainless from the factory, although low-grade stainless so mostly covered in surface rust now. 'Stainless Steel' is a mixture of metals but still contains mostly Steel which is prone to oxidising.

Iainmd is right though, the 'sport' systems have huge tail pipes but I guess you could get them cut off and re-done smaller like the standard ones. Think that's what I would do myself otherwise it'd look weird without the volvo sport rear valence kit. Whichever way you look at it I reckon £600.00 to achieve something like this overall so not to be taken lightly.

[Markos01]

Do some research into good local exhaust garages/fabricators. Explain you don't want an upgrade of any kind or more noise, just a working exhaust system and that Volvo don't sell replacements anymore. Explain the car is only going to last 2-3 years more so you're looking for a cost-effective solution.

[LizardOfBodom]

Im in the same boat (AWD), had the flex pipe replaced once already and had to use muffler shop as the "generic" one used failed within a month so they custom made the flex and matched it to the AWD front curved section. Its less of a problem with rear box as aftermarket ones are available, but the piping for us is more of an issue as its curved differently than any standard FWD T5's.

Bottom line - yes, best option is probably custom-made exhaust, you just specify how normal/sporty you want it to be or that you want something as OEM as possible, theyt will cut and bend pipes to match and use some ready components (like back box) and set it up for your liking.
If Im ever facing this (ie if rest of my car outlive the backbox) I will get them to re-use old tail pipes as I hate the "look-at-my-chimneys" tuning style.

[iainmd]

For reference, here's what Jetex/Ferrita/BSR will look like with and without a rear sport bumper. They look mental without which is why I sourced and fitted the sport bodykit to the SE model I had....

Without - Pic1 Pic2
With - Pic1 Pic2

Hope it's helpful. If you have a Sport or an SE Sport model I can heartily recommend the Jetex as it's barely louder than stock but if you have an SE or S trim model I'd be inclined to go custom fabrication if you can't get an OEM one.

My main objection to the stock exhaust was the downward pointing tips making it look like a diesel of that time. I hated them.

[Brimfull]

it would be more cost effective to stay away from branded exhaust systems as your limited to tail pipe design/loudness and you pay extra £££ for the brand name.