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Discussion Starter · #1 ·
I have a 1994 (1993 1/2) 900 turbo convertible. After pulling it out of storage, I realized that I have an exhaust leak. I understand that the stock exhaust is 2.5" and was thinking of upgrading to 3" exhaust. What problems can I expect if I do this?

I also have not been able to find a cat back system for this car. I specifically want stainless steel construction. Can anyone point me in the right direction to find this elusive system? It appears that no one makes a system for it. I was looking to use a Borla muffler.

If I do go to 3" then I will need a downpipe as well as a 3" cat. This are nearly impossible to find in the us. Can someone help me with a source on this? I would sincerely appreciate any input.
 

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just a heads up oem is 2.25
 

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Deez Nutz
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There will be no "problems" with a 3" exhaust like you are looking for...

The C900 performance parts market is pretty barren, so you are probably going to need to go to an exhaust shop, and have them make you something.

The DP, and the exhaust system is pretty straight forward, as far as bends go. The section over the rear axle is the most complicated part, however, it's not a big deal for a shop.

I would also suggest using a Magnaflow muffler. Turbos do not like exhaust restrictions, and using a baffled Borla might sound neat, but it might negate any potential gains from the 3" system.

I have a magnaflow the size of a pop bottle on my C900, and it sounds great. The turbo makes things pretty quiet in general. If you want a deep tone, look at oval case Magnaflows. They sound neato on Saabs.

Video of my exhaust:
 

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Any good exhaust shop worth their welder should be able to at least make you a 3" custom cat back. I don't know how a Borla will sound on a c900 but lots of people (including me) have had success with Magnaflow.

A 3" DP will take a bit more work, as you usually have to relocate the battery.

Here's my car a few hours after the 3" cat back was installed. (No video since we added a 3" DP, but search YouTube, there's tons.)

 

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Deez Nutz
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A 3" DP will take a bit more work, as you usually have to relocate the battery.
Yep. Totally forgot about that.

Pro-Tip: You can re-use all the factory battery leads when you move the battery.

Disclaimer: This was on my 1986.
 

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Discussion Starter · #6 ·
Thanks for the quick responses. I am not looking for a muffler that is loud as this is my relaxing vehicle. I have read that the Magnaflow mufflers are pretty loud. I just do not want to replace the exhaust with OEM when I can get a little more performance out of it.

What about keeping the downpipe and the cat intact and just replacing from the cat back with 3"?

How much should I expect to spend on this?
 

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Mine is definitely louder than stock but not as loud as Palmer's. Plus I have a convertible so it's always there... and I still love it. :)

My custom cat back was about $550 but included 3" with mandrel bends, new Magnaflow, and a new catalytic converter certified by the State of California Communist Oxygen Society (aka like 3x the price as the other 49 states).
 

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Discussion Starter · #8 ·
I also do not like the backfire noise when you let off of the gas. The new system should not sound like I have a broken exhaust. How do you avoid this?
 

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I have a 3" turbo back exhaust, and also like the magnaflow muffler. I got another 1" of boost with this system on it's own.

I have a 3" downpipe with the battery in the stock location, although the battery is thinner than the stock one. No problems after 4 years.

I had Jak Stoll make mine in stainless, the whole thing cost about $1000.

~Junkie
 

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Deez Nutz
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I had a 3" JT on my 9-3, and it was fine, however shipping from Europe is going to be a bit of money.

Also, considering the conversion rates...at $800 USD for the exhaust you linked to alone, you could have something made, that's probably a bit nicer.

The backfiring is a by-product of a freer flowing system. There will be tradeoffs.
 

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Discussion Starter · #13 ·
So really there are no off the shelf systems. I need to find a local shop who will make a 3" stainless steel exhaust? What about the cat? The standard is 2.25"? Can you find a 3" cat? I do not want to have to deal with inspection issues. That is the reason I am trying to find a quick solution, my inspection is due at the end of the month. I live in NY so they are tough on the inspections.
 

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I just picked up one of Brad from KC SAAB's 3" custom downpipes with the separate pipes for turbo and wastegate ports. I bought it used from an Indy friend of mine. According to him it doesn't require battery relocation. I suppose you could call Brad and see if he's still making them.

Mine hasn't arrived yet, but I'm guessing something like this picture by Jon Williams.

 

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So really there are no off the shelf systems. I need to find a local shop who will make a 3" stainless steel exhaust? What about the cat? The standard is 2.25"? Can you find a 3" cat? I do not want to have to deal with inspection issues. That is the reason I am trying to find a quick solution, my inspection is due at the end of the month. I live in NY so they are tough on the inspections.
Yes they make 3" cats.

Keep in mind you are dealing with a 17-18 year old Swede that was in its last year of production, and has a relatively small enthusiast community. Low demand means low supply for off the shelf upgrades.

Find a good local shop. You should be in an out of there in a 1/2 day and I think you'll be pleasantly surprised at the results. You'll be supporting the local economy, too.
 

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My son had a 3" stainless cat-back system put on his 900T by a local performance exhaust shop--didn't take long. Just be sure you find a place that has a mandrel bender. Most chain shops will just have the standard pipe bender which crimps the bends.
 

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Discussion Starter · #18 ·
I have been unable to locate anyone locally in Buffalo, NY that can do a 3" stainless Steel Mandrel Bent exhaust. I am still looking for other options. Any suggestions?
 

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You wouldn't like the exhaust I had on my vert then...
 
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