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Old 27th October 2011, 15:17   #1
evolve automotive
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Evolve E-Tronic CAT-BACK Valve Exhaust Info

Hi Guys,

since someone leaked the info (yes... Mr Hasan! ) about our recently developed valve operated exhaust system we may aswell make it official!

Evolve E-Tronic Valve Exhaust System - BMW E60 M5 / E63 M6

It's always hard to make an exhaust system which pleases everyone. Some like them loud, some not so. Even in our own case as enthusiasts we understand that there is no perfect exhaust system when it comes to sound level and noise.

So, we came up with a plan to create a system which would appeal to those that like to the best of both worlds with the least amount of compromises.

During the consultation period we spoke to a few M5board members, who we shall name and thank on official launch, about what they though the best ideas would be.

Our Main Objectives:

- Noise levels to be sporty/sophisticated with the valve closed
- Minimal or zero drone with valve closed and open
- Power output not to change with the valve open or closed (This is not easy!)
- Valve open noise to be epic without being too loud/annoying
- Easy of installation of the physical exhaust
- Easy installation of the electronics which control the valve position
- Valve operation to be electronic with a keyfob
- Valve system to be easily removed in case of failure (will come with a lifetime warranty)
- A good range of tail pipes
- Tail pipes to be adjustable so individual stagger or length can be setup depending on individual taste and/or rear diffuser type

Achievements

I am glad to report back that after some good planning and hard work we have something that meets all of the above with the addition of some small details.
The installation of the actual mechanical system is no harder than fitting any other CAT back system.
The installation of the electronics is very very easy and can be completed within 1-2 hours depending on how you route the wiring.
This is an electronically operated system which does not work on engine vaccuum so the installation does not require hose to be routed to the front of the car and plenum removal.
The simple wiring loom goes from the rear exhaust, through any of the numerous gromets on the floorpan and into the trunk and again is very easy to install.
The valve open closing is operates flawlessly and quickly with the keyfob.

The sounds with the valves closed is deep and sporty without any noticeable drone. It is louder than stock but very sophisticated.
With the valve open the exhaust takes on a completely different note which is best described by looking at some of the videos below. Still hardly any drone at crusing speeds which for us is a big achievement.
Of the valve based systems on the market at the moment we have seen many people complaining that the loud setting is so loud that they seldom ever use it. Our system has been designed so that you will actually have a loud setting which sounds great and you won't be embarrassed to use it.

There is no power difference between the open and closed position and this was one of the hardest things to do. It has been reported that many of the current valve systems for the V10 and E92 M3 lose upto 30hp on the closed position and for us this is unacceptable for a performance exhaust.

The finer details have been to place the valve itself in a position where it is invisible from the rear of the car. The rear muffler housings are painted black so the tail pipes are clearer to see and more pronounced. Without the painting we noticed too much reflection from the backplate especially at night and the tail pipes were less visible.
The rear mufflers are also height adjustable to accomodate large rear diffusers or epersonal taste on position.

The tail pipes have been chosen very carefully based on customer feedback.
3 types are available:

1) 4 x 100mm thin rolled edge
2) 4 x 120 x 80mm Slashed Oval
3) 4 x thin edge straight cut

A point on 3). Many manufacturers install thin edge tail pipes which really are too thin and once soot builds up inside the tail pipes are almost invisible from the rear. We have sourced a pipe which is much thicked than normal such that the tail pipes still give that 'race look' but are clearly visible from the rear.

All tail pipes are sold seperately incase you want to change or even have two styles. Again, will mention that are adjustable.

The system will be sold as a CAT-BACK (secondary CAT's). The mid section is a H Pipe and we will offer an X Pipe as an option for the same price.


Images of pre-production system

Rear Silencers with Valves fitted (No paint, no tail pipes)




4 x 100mm tail pipes on evolve V10



Note - rear mufflers are not visible - tail pipes more prominent










4 x 120 x 80 mm Oval
Only 1 image is available from the development:



Further images of the oval and race tail pipes will follow as soon as they arrive from the factory.

The proposed keyfob for opening and closing the valve






Videos of Evolve E-Tronic CAT BACK System with Evolve X-Pipe

Please note that this is only gives an idea of how it sounds. In real life the difference is bigger between the two sound levels and of course as you know, it's very difficult to accurately record sound! Once we are fininshed we will release videos with a stock M5 next to our car.

+ YouTube Video
ERROR: If you can see this, then YouTube is down or you don't have Flash installed.


+ YouTube Video
ERROR: If you can see this, then YouTube is down or you don't have Flash installed.


+ YouTube Video
ERROR: If you can see this, then YouTube is down or you don't have Flash installed.



Your comments as usual are always welcome and I hope you like what we've done!

Last edited by evolve automotive; 27th October 2011 at 15:56.
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Old 27th October 2011, 15:19   #2
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When will these start being offered for sale? Those round tips are wicked!

Last edited by robcassell; 27th October 2011 at 15:20.
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Old 27th October 2011, 15:38   #3
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Quote:
Originally Posted by robcassell View Post
When will these start being offered for sale? Those round tips are wicked!
Lead time is around 4 weeks and it will improve once production sets in.

The round tips - everyone has commented on these! They do look fantastic.
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Old 27th October 2011, 16:52   #4
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Hi Sal!

Sorry for leaking out your development. It became irresistable.

I love the workmanship and the build quality. Absolutely gorgeous.

I would perfer the round tips 4 x 100mm thin rolled edge. Really love them. I have never liked the oval tips.

As for the sound, I really like the sound with the valves closed. Perhaps I am getting a bit old now.

I also like the fact that the buyers will be able to swap the tips and that the valve system comes with a life time warranty.

I congratulate you and the boys at Evolve Automotive for developing products that cater for the requiremenst of maximum enthusiasts. And I thank you for always being open to suggestions and actually using the feedback from the enthusiasts in your products.
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Old 27th October 2011, 17:22   #5
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Dyno Tests:





Video is about to be uploaded showing the same runs as above.

As you can see - No measurable difference between the valves being open or closed making the system probably of the only ones that doesn't lose power when the valves are closed.
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Old 27th October 2011, 17:47   #6
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Wow, finally a valvetronic exhaust system that doesn't lose power. Some nice features to boot, adjustable tips and from looking at the muffler pictures, the mufflers can be adjusted up/down. This seems like an excellent alternative for folks that don't want overly obnoxious exhaust noise. Btw, the 100mm tips look awesome. Good job Sal!
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Old 27th October 2011, 18:02   #7
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Sal! What other mods does this car have.

Are the manifolds stock? What about the secondary cats?
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Old 27th October 2011, 18:20   #8
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Quote:
Originally Posted by Hasan Shaikh View Post
Sal! What other mods does this car have.

Are the manifolds stock? What about the secondary cats?
The car is 100 stock other than a speed delimit.

We will next replace section 1 with high flow secondary CAT's.

Then the upcoming tubular headers and/or race headers.

That's then our S85 exhaust range done.

Small options will follow like different finished tail pipes (Black Chrome etc).
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Old 27th October 2011, 18:21   #9
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Quote:
Originally Posted by tju317 View Post
Wow, finally a valvetronic exhaust system that doesn't lose power. Some nice features to boot, adjustable tips and from looking at the muffler pictures, the mufflers can be adjusted up/down. This seems like an excellent alternative for folks that don't want overly obnoxious exhaust noise. Btw, the 100mm tips look awesome. Good job Sal!
You have been extremely helpful in our development proceedure with some excellent ideas and recommendations for noise type.

We cannot thank you enough Travis.

You are an asset to both us as a developer and the community.
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Old 27th October 2011, 18:28   #10
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I'm liking the #'s, look, AND SOUNDS

+1
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