Elise S 2ZR-FE Exhaust Comparison Featured

 

2bular Vs. Hangar 111

I was intrigued by Hangar 111’s claim “ we went back to the drawing board to re-invent the sports exhaust”.
I’ve been designing and building “Sports Exhausts” for over 30 years and decided to compare my 2ZR system with the Hangar 111 exhaust supplied to a 2ZR owner.
Check out the results below!




Compared to the 2bular design, the exit pipework from the Hangar 111 silencer has an awkward mismatch in the bend radius.  Their pipe is only 60mm diameter – 2bular 63.5mm.
The oval tip is very small and doesn’t fill the diffuser exit. It’s the only part of the exhaust you can actually see – so they might have made the effort!:




You need the larger bore on a supercharged install.
An e-mail from the disgruntled 2ZR owner told me this Hangar 111 exhaust was “unbearable” – LOUD and dronnnnnney. It is a 7”dia silencer. The minimum silencer diameter I use on these cars is 8” – that 2ZR motor with its long stroke is VERY vocal.
Some aftermarket companies look to cover most of the Lotus exhaust world with ONE exhaust design. Only 2bular design and build an exhaust for EACH Toyota motor. Dronnnnnne is a common fault reported to me by customers of other aftermarket exhaust suppliers. It is NEVER a case of TADTS (They All Do That Sir). If you try and fit the same design to the Elise 1ZR AND the Elise 2ZR – you will have problems – LOUD and dronnnnnning problems.
Now, a “Sports Exhaust” should at least improve performance by providing an easier path for the gas-flow. Normally, this is a “straight-thru” exhaust design. You can see the factory design is a “Z-Flow” layout (or 3-way) with the gas-flow interrupted and reversed twice to allow the sound to be controlled better – restrictive and not great for performance. Standard fare for a factory system though.
Hangar 111’s “re-invention” of the sports exhaust is even more restrictive, almost labyrinthine in its layout as you can see below. From the simple 3-way factory system:



to this:



After the entry pipe, the gas-flow is split in two – this may be where the dronnnnnne issue is caused.



The final section is problematical. The divided gas-flow is reversed through the restrictive perforated baffles, then finally out through the swaged section with its holed circumference. This section is where I think control of the sound is lost - hence the LOUD issue.

Hangar 111 claim construction is 304 Stainless Steel (non-magnetic) but I found mild-steel parts internally – not great for longevity.

So, “re-inventing the sports exhaust” according to Hangar 111 apparently means producing a LOUD, droning exhaust which will rust internally.

IMPORTANT: I advised the 2ZR owner to claim a full refund from Hangar 111 but he was told as the system had been “used” that was not possible. Mr Greg Lock – Managing Director of Hangar 111 Ltd – told him he would “ask around the race teams if they would take it off his hands”. 2ZR owner is still waiting.
When you buy an aftermarket product you MUST ask the right questions and get the answers in writing. If the 2ZR owner had asked if the Hangar 111 dronnnned at all and had a negative reply he would have had a very strong case for a full refund. Under the Consumer Rights Act 2015, all products must be fit for purpose and as described. The fact that the exhaust has been “used” doesn’t matter! How else do you find out if it’s as described?! Your local Trading Standards Office will be delighted to help you, especially if you have written claims of quality and fitness for purpose.


 

 

2bular Vs. Stg3 Exhaust:

 


The Stg3 exhaust was introduced specifically for the supercharged 2zz motors and dealers were warned NOT to fit the restrictive Stg2 to supercharged cars.
The Stg3 had a 7”diameter silencer, 19” long with the same big 6x4 oval tip from the OEM system.



A quick run in the car and I thought it sounded rather good. Unfortunately, the dronnnnnnne was ……………… not rather good!
Checking out the design showed an off-set entry to the silencer (to push the body inwards away from the rear heat-shield/grilles).



And a central exit!



To link the entry/exit the perforated core pipe has been angled up. Doing this means the exhaust gases actually blow through the perforations, pressurising the internals of the silencer and blowing the packing materials out through the tailpipe. Blowing the sound energy through those holes makes for a wonderful wind instrument – guaranteed dronnnnnnne, especially with an empty can.


Here’s the REALLY important bit. During R&D on the 2zr cars, I found a 7”diameter silencer was just too damned LOUD for comfortable, everyday use.

I dropped the 7” option from my 2zr page and only recommend an 8”dia silencer. I offer an H1 (quieter) version with one resonance chamber for better noise-control and I have the new QP (Quiet Performance) system with TWO resonance chambers for below 95dbs. The 2zr is an extremely vocal motor.


Summary: the Stg3 is okaaaaay on the car it was developed for – the supercharged 2zz. The silencer diameter is too small to control the noise of the 2zr and it has the wrong bore – so on these cars, it’s too LOUD and it dronnnnnnnes.

 

Author

Jim@2bular

Master Craftsman in all exhaust systems

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