Exhaust Valve/Flap Bypass (Passive) - Beta testers wanted
#1
Exhaust Valve/Flap Bypass (Passive) - Beta testers wanted
Hi all, I've spent the past month or so developing my take on the exhaust valve/flap bypass to keep it open cheaply! After some poking and prodding, the car as stock will cycle the flappers when the engine fires up and when it shuts down. If you simply unplug or mechanically disconnect the flapper motor from the flaps, you will get a CEL (at least for my '23 G550).
I didn't want to pay close to $1,000 (before installation) to semi-permanently add remote control to my exhaust valves when I know I just wanted to keep them open. I also didn't want to reprogram the car because who knows what that might do to my warranty.
I knew I could design something simple that installs very quickly. It only takes about 10min per side and can easily be put back to stock without any trace of the mod. It is simple enough that even non-DIY'ers can confidently install it. The flapper motor sits higher now but even when pushing the exhaust up as hard as I could, it still did not cause any interference or contact.
So I have been enjoying my exhaust notes open and flowing for the past month but now looking for testers who want to try it for free. I am targeting the final kit cost to be ~$100 (CNC machined and anodized aluminum) depending on the level of interest.
And now for some pictures of the prototypes/beta test kit. They all worked well but the early designs used a rigid connection pin and I worried about putting additional stress on the flapper motor. The latest design reuses the original connection spring so it functions nearly the same as the factory setup.
The end goal is to cheaply fool the flapper motor without any adverse effects - using parts that are easily and quickly installed/removed without leaving a trace.
Current iteration fully assembled
Current iteration body mounted
Exhaust flap safety wired open
Summary of iterations
Third (current) iteration with a sintered body and reused connection spring from OEM
Second iteration with a CNC machined and anodized body and sintered connection pin
First iteration with a sintered body and dowel connection pin
Aaaand here's the kit I made to finally add a real lock to the spare tire cover
https://mbworld.org/forums/g-class-w...k-adapter.html
I didn't want to pay close to $1,000 (before installation) to semi-permanently add remote control to my exhaust valves when I know I just wanted to keep them open. I also didn't want to reprogram the car because who knows what that might do to my warranty.
I knew I could design something simple that installs very quickly. It only takes about 10min per side and can easily be put back to stock without any trace of the mod. It is simple enough that even non-DIY'ers can confidently install it. The flapper motor sits higher now but even when pushing the exhaust up as hard as I could, it still did not cause any interference or contact.
So I have been enjoying my exhaust notes open and flowing for the past month but now looking for testers who want to try it for free. I am targeting the final kit cost to be ~$100 (CNC machined and anodized aluminum) depending on the level of interest.
And now for some pictures of the prototypes/beta test kit. They all worked well but the early designs used a rigid connection pin and I worried about putting additional stress on the flapper motor. The latest design reuses the original connection spring so it functions nearly the same as the factory setup.
The end goal is to cheaply fool the flapper motor without any adverse effects - using parts that are easily and quickly installed/removed without leaving a trace.
Current iteration fully assembled
Current iteration body mounted
Exhaust flap safety wired open
Summary of iterations
Third (current) iteration with a sintered body and reused connection spring from OEM
Second iteration with a CNC machined and anodized body and sintered connection pin
First iteration with a sintered body and dowel connection pin
Aaaand here's the kit I made to finally add a real lock to the spare tire cover
https://mbworld.org/forums/g-class-w...k-adapter.html
Last edited by myfirstg; 06-12-2023 at 08:52 PM.
#2
Cool little mod. What material are you using in the beta version? Looks almost 3D printed, but I assume it's metal or some sort?
#3
Super Member
Just came here to say that you are very talented!
I am having the coding done so I can keep my exhaust open or closed using the factory button, but this is a neat option.
I am having the coding done so I can keep my exhaust open or closed using the factory button, but this is a neat option.
#4
Thanks guys. What does the open exhaust flap button look like? It's an AMG only thing right?
The current prototype is 3d printed by sintering aluminum powder. Some of the previous parts were made from stainless steel powder.
The current prototype is 3d printed by sintering aluminum powder. Some of the previous parts were made from stainless steel powder.
#5
Super Member
So your mod should make the exhaust overall much louder at all RPM's.
As you mentioned, these are the current other options:
Via computer programming:
https://mwmods.com/index.php/product...ule-w463-g500/
Via extra remote:
https://www.renntechmercedes.com/ind...490-463-detail
Below is a stock photo of the exhaust button that the AMG's have.
#6
Out Of Control!!
Join Date: Dec 2019
Location: Toronto, Canada
Posts: 14,649
Received 2,813 Likes
on
2,395 Posts
PFL205.064 with M276.823 (Oil pump solenoid defeated)
Hi all, I've spent the past month or so developing my take on the exhaust valve/flap bypass to keep it open cheaply! After some poking and prodding, the car as stock will cycle the flappers when the engine fires up and when it shuts down. If you simply unplug or mechanically disconnect the flapper motor from the flaps, you will get a CEL (at least for my '23 G550).
I didn't want to pay close to $1,000 (before installation) to semi-permanently add remote control to my exhaust valves when I know I just wanted to keep them open. I also didn't want to reprogram the car because who knows what that might do to my warranty.
I knew I could design something simple that installs very quickly. It only takes about 10min per side and can easily be put back to stock without any trace of the mod. It is simple enough that even non-DIY'ers can confidently install it. The flapper motor sits higher now but even when pushing the exhaust up as hard as I could, it still did not cause any interference or contact.
So I have been enjoying my exhaust notes open and flowing for the past month but now looking for testers who want to try it for free. I am targeting the final kit cost to be ~$100 (CNC machined and anodized aluminum) depending on the level of interest.
And now for some pictures of the prototypes/beta test kit. They all worked well but the early designs used a rigid connection pin and I worried about putting additional stress on the flapper motor. The latest design reuses the original connection spring so it functions nearly the same as the factory setup.
The end goal is to cheaply fool the flapper motor without any adverse effects - using parts that are easily and quickly installed/removed without leaving a trace.
https://cimg3.ibsrv.net/gimg/www.mbw...bface0be3f.jpg
Current iteration fully assembled
https://cimg5.ibsrv.net/gimg/www.mbw...b26b50ecfe.jpg
Current iteration body mounted
https://cimg8.ibsrv.net/gimg/www.mbw...bd0535d814.jpg
Exhaust flap safety wired open
https://cimg9.ibsrv.net/gimg/www.mbw...aa1aaf7ad7.jpg
Summary of iterations
https://cimg1.ibsrv.net/gimg/www.mbw...c6cc62de47.jpg
Third (current) iteration with a sintered body and reused connection spring from OEM
https://cimg5.ibsrv.net/gimg/www.mbw...2116a0d970.jpg
Second iteration with a CNC machined and anodized body and sintered connection pin
https://cimg9.ibsrv.net/gimg/www.mbw...45bd653234.jpg
First iteration with a sintered body and dowel connection pin
Aaaand here's the kit I made to finally add a real lock to the spare tire cover
https://mbworld.org/forums/g-class-w...k-adapter.html
I didn't want to pay close to $1,000 (before installation) to semi-permanently add remote control to my exhaust valves when I know I just wanted to keep them open. I also didn't want to reprogram the car because who knows what that might do to my warranty.
I knew I could design something simple that installs very quickly. It only takes about 10min per side and can easily be put back to stock without any trace of the mod. It is simple enough that even non-DIY'ers can confidently install it. The flapper motor sits higher now but even when pushing the exhaust up as hard as I could, it still did not cause any interference or contact.
So I have been enjoying my exhaust notes open and flowing for the past month but now looking for testers who want to try it for free. I am targeting the final kit cost to be ~$100 (CNC machined and anodized aluminum) depending on the level of interest.
And now for some pictures of the prototypes/beta test kit. They all worked well but the early designs used a rigid connection pin and I worried about putting additional stress on the flapper motor. The latest design reuses the original connection spring so it functions nearly the same as the factory setup.
The end goal is to cheaply fool the flapper motor without any adverse effects - using parts that are easily and quickly installed/removed without leaving a trace.
https://cimg3.ibsrv.net/gimg/www.mbw...bface0be3f.jpg
Current iteration fully assembled
https://cimg5.ibsrv.net/gimg/www.mbw...b26b50ecfe.jpg
Current iteration body mounted
https://cimg8.ibsrv.net/gimg/www.mbw...bd0535d814.jpg
Exhaust flap safety wired open
https://cimg9.ibsrv.net/gimg/www.mbw...aa1aaf7ad7.jpg
Summary of iterations
https://cimg1.ibsrv.net/gimg/www.mbw...c6cc62de47.jpg
Third (current) iteration with a sintered body and reused connection spring from OEM
https://cimg5.ibsrv.net/gimg/www.mbw...2116a0d970.jpg
Second iteration with a CNC machined and anodized body and sintered connection pin
https://cimg9.ibsrv.net/gimg/www.mbw...45bd653234.jpg
First iteration with a sintered body and dowel connection pin
Aaaand here's the kit I made to finally add a real lock to the spare tire cover
https://mbworld.org/forums/g-class-w...k-adapter.html
#7
Member
Have you tried these on a G63 yet? I had the Renntech module on a 2021 G550 that worked well but was a pain to install. I haven't done anything to my G63 but would certainly help you test it out. I actually work in the automotive aftermarket corridor and have my entire adult life. I applaud the effort here. Looks well done.
Trending Topics
#15
Hi very interested in this I cannot PM you since I am new can you please PM me?
Hi all, I've spent the past month or so developing my take on the exhaust valve/flap bypass to keep it open cheaply! After some poking and prodding, the car as stock will cycle the flappers when the engine fires up and when it shuts down. If you simply unplug or mechanically disconnect the flapper motor from the flaps, you will get a CEL (at least for my '23 G550).
I didn't want to pay close to $1,000 (before installation) to semi-permanently add remote control to my exhaust valves when I know I just wanted to keep them open. I also didn't want to reprogram the car because who knows what that might do to my warranty.
I knew I could design something simple that installs very quickly. It only takes about 10min per side and can easily be put back to stock without any trace of the mod. It is simple enough that even non-DIY'ers can confidently install it. The flapper motor sits higher now but even when pushing the exhaust up as hard as I could, it still did not cause any interference or contact.
So I have been enjoying my exhaust notes open and flowing for the past month but now looking for testers who want to try it for free. I am targeting the final kit cost to be ~$100 (CNC machined and anodized aluminum) depending on the level of interest.
And now for some pictures of the prototypes/beta test kit. They all worked well but the early designs used a rigid connection pin and I worried about putting additional stress on the flapper motor. The latest design reuses the original connection spring so it functions nearly the same as the factory setup.
The end goal is to cheaply fool the flapper motor without any adverse effects - using parts that are easily and quickly installed/removed without leaving a trace.
Current iteration fully assembled
Current iteration body mounted
Exhaust flap safety wired open
Summary of iterations
Third (current) iteration with a sintered body and reused connection spring from OEM
Second iteration with a CNC machined and anodized body and sintered connection pin
First iteration with a sintered body and dowel connection pin
Aaaand here's the kit I made to finally add a real lock to the spare tire cover
https://mbworld.org/forums/g-class-w...k-adapter.html
I didn't want to pay close to $1,000 (before installation) to semi-permanently add remote control to my exhaust valves when I know I just wanted to keep them open. I also didn't want to reprogram the car because who knows what that might do to my warranty.
I knew I could design something simple that installs very quickly. It only takes about 10min per side and can easily be put back to stock without any trace of the mod. It is simple enough that even non-DIY'ers can confidently install it. The flapper motor sits higher now but even when pushing the exhaust up as hard as I could, it still did not cause any interference or contact.
So I have been enjoying my exhaust notes open and flowing for the past month but now looking for testers who want to try it for free. I am targeting the final kit cost to be ~$100 (CNC machined and anodized aluminum) depending on the level of interest.
And now for some pictures of the prototypes/beta test kit. They all worked well but the early designs used a rigid connection pin and I worried about putting additional stress on the flapper motor. The latest design reuses the original connection spring so it functions nearly the same as the factory setup.
The end goal is to cheaply fool the flapper motor without any adverse effects - using parts that are easily and quickly installed/removed without leaving a trace.
Current iteration fully assembled
Current iteration body mounted
Exhaust flap safety wired open
Summary of iterations
Third (current) iteration with a sintered body and reused connection spring from OEM
Second iteration with a CNC machined and anodized body and sintered connection pin
First iteration with a sintered body and dowel connection pin
Aaaand here's the kit I made to finally add a real lock to the spare tire cover
https://mbworld.org/forums/g-class-w...k-adapter.html
Hi very interested in this I cannot PM you since I am new can you please PM me?