E-Class (W211) 2003-2009

S211 E500 Exhaust modification

Old Sep 27, 2020 | 06:45 PM
  #1  
honyock's Avatar
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E500 4matic wagon
S211 E500 Exhaust modification

After repairing my primary cat this weekend and having most all of the exhaust off, I finally have a good plan of action how I am going to be installing an x-pipe and individual resonators on my E500 in place of the secondary cats and the resonator.

It looks like if I cut off the secondary cats and move the offset forward just after the mounting points on the transmission crossmember I will gain the space I need for the slightly longer catback from the Chrysler LX chassis I snagged.

I am going to replace the tailpipes at the same time, though I am stuck running some sort of mufflers with turndowns since no one seems to make a S211 rear bumper with cutouts anymore (at least not in the US that I have found actually in stock...)

I am upsizing to 2.75" because that is what I happened upon. Modifying the exhaust to add the mounting points will be easy enough. Hopefully if I do it right, the stock exhaust will be easy to put back on with a simple butt joint clamp.

Not a welder, but it is good enough for government work... The Harbor Freight 180A MIG isn't the greatest piece of equipment, but if it has a good spool it is at least pretty consistent. I think my fix for the cat will work for a while (once I get my new motor and trans mounts installed at least. I didn't waste time grinding off the spatter since it is hidden, and thinking I may go to a midlength header down the road if I can pick up something cheap enough like a used set of Kleemann or the Eurocharged style.





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Old Sep 28, 2020 | 12:30 PM
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AeonTheTerrible's Avatar
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W211 E500
What sort of sound are you going for?
The E500 has a fine line between being refined but loud, and obnoxious Honda Civic at 3AM loud, so be careful in that regard, since it really is a luxury vehicle.

I could have sworn that Suvneer used to have the wagon bumpers--could very well be wrong. If you don't have any options, though, you can do custom cutouts in your bumper. There are templates all over the place for this mod.
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Old Sep 28, 2020 | 05:50 PM
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honyock's Avatar
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E500 4matic wagon
Originally Posted by AeonTheTerrible
What sort of sound are you going for?
The E500 has a fine line between being refined but loud, and obnoxious Honda Civic at 3AM loud, so be careful in that regard, since it really is a luxury vehicle.

I could have sworn that Suvneer used to have the wagon bumpers--could very well be wrong. If you don't have any options, though, you can do custom cutouts in your bumper. There are templates all over the place for this mod.
The one brand I contacted (might have been duraflex) said that the S211 are no longer made. I don't see anything for s211 on Suvneer site.

I have a Corsa catback minus the mufflers since they would have been difficult to use with my bumper anyway. I tested the x pipe and resonators on my 7.5l truck. With just the resonators it would be plenty quiet with an 5.0l engine...I am also planning on running some small mufflers with turndowns on the 2.75" tailpipes. but first I am going to just try the stock mufflers without secondary cats and the x-pipe/larger diameter individual resonators. The Corsa resonators are like super long glasspacks so they quiet the exhaust pretty well.

I don't really want the huge twin tip look of a AMG car or anything, and the sort of incognito look of hidden tips is fine with me vs. the cheap look of holes cut without some sort of trim rings or other designed look instead of just a hacked add-on.
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