Has anyone cut out the stock muffler and installed an aftermarket muffler, such as Borla? I've seen the mufflers available on Ebay in 2.25" and 2.5" for around $75-80.

ahhhh..yeah.

Calmini

Not the whole system, just replacing the MUFFLER.

I was gonna get a Calmini catback system, but after considering the options (read: price vs. gain) I decided to go with a Flowmaster muffler only. The exhaust system from the cat converter forward still presents the same amount of restriction, so increasing the pipe from there back adds little value (unless your OEM pipe is rusted out or damaged). The Flowmaster is overall a much better muffler than the one that comes with the catback system. I decided to leave the little resonator behind the muffler(?) in place and the resulting exhaust tone ended up being just right.

The jury's still out on performance/mileage, but my X seems a bit peppier and my last two tanks showed about 20 miles more per, but I'm reserving further comment until I put some more miles on with the new muffler. It DOES sound cool as shit, tho...and the best part was that installed it cost me way less than half of the Calmini without adding in the installation and shipping cost. So the ol' tailpipe is still there - BFD

with that said, what would the difference be between the Calmini catback and supercharged catback? Can it just be marketing?

which model flowmaster did you install and what was the pipe diameter at the ends?

The S/C Calmini cat-back has an extra member. It's kinda like an extension piece. The stock S/C and non-S/C are different, so this extra extension makes up for the difference.

It was hell getting off my stock muffler; It broke free, but it would not pull out because of the indentation that that stock U clamp made. I had to cut a slit in the stock pipe and then it pulled free.

I was planning to pick up the Flowmaster or Borla catback exhaust since they do come stainless, but learning that there is a difference between the Calmini SC and non-SC model just further confuses me. The extra part that the Calmini-SC, what does it do? And would it really matter much, that the Flowmaster and Borla model may or may not have specific models for a Xterra SC? Any input would be appreciated. Thanks....

I did exactly that. I cut out the stock muffler and welded on a 2 1/4" double offset Borla universal muffler. It's much cheaper than a whole system and you get the same result. It sounds nice plus I've notice a SLIGHT difference in performance and gas mileage.

Here is the best site for cheap exhaust parts:

http://www.exhaustproslinc.com/borstainstee.html

thanks mummer, thats the response i was hoping to get. what diameter muffler did you get? any other parts used for installation? how was the removal of the stock muffler, a pain or??

The diameter was 2 1/4". I took it to a muffler shop to have it done, so I don't know how much work was involved. The Borla muffler is much smaller than the stock one, so I think they had to weld in a piece of pipe. I really love the way it sounds.

Mummer,

How much hp/tq gain and mpg increase did you notice?

Sounds like welding would involve a lot of work. How much do they charge you for labor?

I've been thinking about replacing my muffler as well, but just hadn't gotten around to saving up $250 for a Calmini one... but may go the Flowmaster/Borla route now. The thing I don't want is an IN YOUR FACE stinkin LOUD muffler. I'm looking for a nice low rumble to let people know that yes, this is a truck, not a car. What kind of sound does yours have? And I too would like to know how much the installation and the whole bit cost.
Thanks

A friend of mine had a borla on his V6 Toyota and it sounded good. Didn't sound like DJ Trevor's pimped out '89 Honda Civic driving by the Food Court at the mall.It was quiet at idle but sounded good when you gave it some gas.

Vector,

If you've been around these boards long enough, you'd know that I can't answer that question. I haven't had my truck dynoed, so I can't give an exact number of horses the filter and muffler added. All I can say is it feels like it has more pick up.

As for the gas mileage, I didn't calculate it, but I know that I fill my tank less often for the same amount of driving.

Poorboy,

I think I paid like $90 for the muffler including shipping and I paid another $50 or so to have it installed.

I was nervous about how it would sound, but I'm very happy. It's a nice deep rumble which isn't noticeable at cruising speeds. I highly recomend it.

Thanks Mummer, sounds like a good deal. Which model did you get? I went to that link you posted and there were quite a few...
Thanks

Poorboy,

I got the Borla XS Turbo offset/offset with 2 1/4" inlet/outlet. It's the stainless steel model.


http://www.exhaustproslinc.com/bortur22ofsa.html

You can also find the Borla mufflers on Ebay. I just purchased one for $86. Can't wait to get it installed.

Let me know what you think. Which one did you get?

I bought a Borla Pro XS Performance Muffler 2.25". Should be coming in the mail soon. The X is way too quiet, I liked it before because you could hear the supercharger kick in but I want something with a nice exhaust tone to it too.

You'll like the Borla, it sounds really nice.

Hey, let us know how the install was and how you like the sound.

I used a Magnaflow thats 6in. round by 21in. long with a 2 3/4 in. i.d. in & out tube and stainless steel. Also custom pipes from the stock flang behind the Y- pipe out to the back the hole system hangs nice and high not to be in the way and I made all the pipes as striaght as possible still with the 2 3/4 . The thing sound super with a open throttle and nice and tame while cruising. Cost $270.00 CND. My fuel mileage got better after the install too.

Did the larger diameter pipes affect your low end torque?