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TRIPLE BYPASS SPECIAL

In early December,” Gil Palmer told us, “I had a triple bypass operation. I was unable to work or drive. I was bored each day.” On his daily walk he had to go right past his new ’04 Chevy Silverado pickup in the garage. The glimpse at his truck before each walk served as a motivator, and he started imagining things that he could do while he was forced to keep it parked next to his previous project.

40 Years Later

Carl Casper’s name has been synonymous with the custom car movement for a long time. As a teenager, Casper created his famous ’51 Chevrolet custom, the Exotic Empress. The car went on to win the 1961 NHRA National Custom Car Championship. (You know it was a long time ago if NHRA was promoting car shows!) Carl Casper is a talented guy who can perform virtually every task required to build a world-class custom car, from metal fabrication to paint and upholstery, and while many of his creations took the form of wild custom cars, they were all driveable.

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MORE POWER? BETTER SOUND? OF CORSA!

Installing Corsa RSC Mufflers and an X-Pipe on an ’05 Mustang

Author

Will Smith

Story & Photography

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The Zing Factor in the Exhaust Market

In order to thrive in the exhaust market, a company must have products with a zing factor. For Corsa, the difference begins with its materials, production techniques, and efficiency of its designs. Corsa uses T-304 stainless steel, which makes each exhaust system effective, durable, attractive, and easy to clean. A good grade of stainless steel makes the process of cleaning pipes about as easy as scrubbing with a Scotch-Brite pad.

Reflective Sound Cancellation Technology

However, other companies also offer T-304 stainless construction, so what really sets Corsa exhausts apart? The answer is Reflective Sound Cancellation technology, a unique approach to muffler design that eliminates fiberglass insulation and other older technologies in favor of a targeted sound-reduction approach. Every vehicle has a speed at which the exhaust drones, which causes an unpleasant moment when the sound waves just seem to hang. You may have noticed this droning in your own car, and after a while, it can really become obnoxious. Corsa tests every vehicle to determine the exact frequency that this droning produces, and then mufflers are designed to create a sound wave that is 180 degrees out of phase with the drone. This process eliminates the droning noise entirely while leaving the rest of the exhaust note intact. The result is a remarkably crisp, clean engine note that brings out the intended sound of the exhaust. To generate this canceling sound wave, each muffler features a carefully sized canister and internal walls that reflect sound rather than damp it.

Enhancing Mustang Exhaust Systems

Unlike those on earlier Mustangs, Ford actually did a decent job with the exhaust systems on the S917 platform. The piping is crafted from stainless steel, and at 2-1/2 inches in diameter, it flows very well, which is good news because it eliminates the need for a traditional after-cat system. Instead, Corsa makes it possible to achieve impressive performance gains with an axle-back system consisting only of new mufflers. Corsa claims gains of 13 hp and 9 lb-ft of torque at the wheels, making this upgrade a high-horsepower-per-dollar investment. But if you want to take your exhaust even further, Corsa also offers an X-pipe that replaces the factory H-pipe. It offers better sound and performance, and it shaves 2 pounds of weight from the exhaust. We understand that weight saving may not be your primary reason for buying this system, but it is a nice bonus.

Installation at Dream Car Factory

During our visit to the Dream Car Factory (800/977-9894) in Streetsboro, Ohio, the crew was fitting one of its DCF500GT Mustangs with the Corsa system. The DCF installs Corsa exhaust on each 500GT it builds because the system’s improved sound, looks, and performance complement this limited-edition Mustang. Your Mustang will benefit from the system, too, and the installation will take no more than a few hours. The only special tool you’ll need is a pipe cutter, and when you’re finished you’ll appreciate your Mustang in a completely new way.

Removing the stock mufflers is easy. Loosen the hose clamp that secures them to the exhaust pipes and remove the rubber hanger above the exhaust tip.

The good thing about the over-axle pipes is that they’re made from stainless steel and actually flow very well. However, you will have to cut them to install the X-pipe. Measure and mark 20 inches back from the rear of the crossover tube on each pipe.

On the driver’s-side cat-pipe, measure 10-1/4 inches back from the exhaust hanger. On the passenger side, measure and mark 10 inches back from the hanger. Here, the installers mock up the X-pipe to make sure that their measurements look correct.

Use a pipe cutter to cut the H-pipe at the marks you’ve just made.

Compared to this section of H-pipe, the new X-pipe will flow much better and will provide more power and better sound. The diameters of the pipes are identical at 2-1/2 inches.

It is best to remove the over-axle pipes and to cut them on a bench vise. Be sure not to over-tighten the vise and crush the pipes.

It’s a good idea to file the edges of your cut before you try to install the new X-pipe.

Install Corsa’s provided clamps, slide the new X-pipe over the stock cat-pipes and then tighten the clamps.

Corsa provides new clamps for the over-axle tubes as well. Slide those tubes into place but don’t completely tighten the clamps yet.

Obviously, the Corsa muffler is much smaller than the factory piece. The polished exhaust tip really sets off the look of the Mustang.

Transfer the exhaust hangers from the old muffler to the new one and then install the new muffler.

The new X-pipe looks good.