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  • FAE Muffler Bypass

    • Year: 2001 Brand: Malibu Model / Trim: Sunsetter VLX Cost: $0-$249 Installation Shop: My garage Engine Type: Indmar LS1

    I did the FAE muffler bypass at the beginning of this season.  I already have the FAE and built a custom surf flap due to the FAE destroying the wave.

    - Price was high for what you get - $190.25 shipped
    - Lack of mandrel bends is unfortunate, as is being totally unfinished
    - Fit was decent.  One side fit better than the other (I think it was the starboard side that had the better fit).  Regardless, no issues with 60+ hours on them so not a problem and I never fiddled with them once post initial install.  Paint held up well; just did a ton of thin rattle can coats of high temp paint.

    Performance Review
    - Performance gain for sure.  I lost about 5MPH when I installed the FAE originally.  I gained a little back going to a 15" prop.  The bypass gained me an additional 1MPH - all measured by two different GPS units on the same water/conditions/loads and is consistently repeatable.  100% factual that the bypass increases power.
    - It is noticeable how much more water comes out of the FAE pipe vs the weep holes when on the hose at idle - obviously less back pressure in the exhaust system
    - Sound wise, I think it sound the same except at WOT, where the boat got a bit more of the aggressive sound back.  My buddy who is with us most times out thought it was a little quieter.  For certain it isn't any louder
    - Space increase is significant.  Far easier to work on that part of the motor now with no muffler.

    Fairly straight forward.  The only hard part is getting the old rubber couplers off.  Just takes a lot of twisting, pushing, turning and some use of a screwdriver to pry it free.  Paint in the butt - putting the new unit on is cake.  Painting the pipes was nothing more than a ton of thin coats with 500 degree high-temp paint, hanging them in the air with a wire hanger to get full coverage.  

    Pics below.  It is a worthwhile mod but for the price should come either painted or polished SS and be mandrel bends...heck, I'd pay a little more for a mandrel bent SS product.  

















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    Did you consider powder coating the exhaust pipes? I'm doing an install of the muffler bypass today and was thinking of ways to finish the pipe. Just wanted to see if you went down that path and gained any good info about the powder coating. 

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    31 minutes ago, safegate said:

    Did you consider powder coating the exhaust pipes? I'm doing an install of the muffler bypass today and was thinking of ways to finish the pipe. Just wanted to see if you went down that path and gained any good info about the powder coating. 

    Nope - cost/time benefit made no sense to do so.  Can of high temp paint was under $10.  Was able to spray in my back yard when doing other stuff, so very little time spent on it.

    Powder coating would cost more for sure. Then driving to the place at their hours, explain what I want, picking it back up, etc.  That's a couple of probably inconvienent hours and the pipes would likely look nearly the same.

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    @Nitrousbird did you run 3.5" inside the boat or 4"?      I'm working on exhaust project now... My manifolds exit at 4" and I was debating keeping them 4" to the transom or 3.5".    I really don't think it will matter performance wise.   Won't need reducers if keep at 4", but mildly easier to create a Y with 3.5 into 4".    8.1 motor... great torque but none of these boats are extreme HP.    I'll be going to single surf exhaust out the back.    

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