Vibrant Ultra Quiet Resonator Noise Solution
I may be one of the oldest Speed3 freaks here at 58 y/o. I've played with turbocharged toys of various types, mostly SAAB's and Volvo's for quite a few years, but had to jump on the MS3 when I saw how the engine was designed and tuned from the factory and how it would probably be easy to make more speed safely.
I had already moved past the "loud is better" phase of my life quite a while back after going through SAAB and Volvo versions of the same issues posted here about the droning and increased noise when freeing up the exhaust. I prefer very free flowing exhausts that are "stealthy" in cars that look stealthy. So, after playing with my MS3 for a while, here's the results of my efforts to get power and keep the sound subdued.
1. Past experience in European turbo cars suggested that there was probably an emissions based restriction in the downpipe before the first cat and perhaps another one after that cat and before the second cat. People here have already figured out that adding a race pipe, especially a 3 inch one, does help a bit, but not that much. Eliminating the second cat does increase noise and droning a bit because the cat does have the secondary effect of toning town the volume, and does produce a few ponies by eliminating some restriction, but gains are modest.
2. It is well known that big downpipes tend to really help turbo engines, especially in the midrange and when the turbo is under full boost. Eliminating the restriction in the stock DP and MP and replacing both with straight through, no cat, 3 inch pipes should realize very significant increases in power but with attendant increased volume and droning. If you willing to live with the noise and want the power, that's the way to go if you are like me and live in a state with no emission inspections. If you want the power and still be stealthy, (or don't like the headaches from the droning) a little more thought goes into the solution.
So, I ended up getting the TurboXS combo "stealth back" which is their 3 inch flex DP and 3 inch flex MP with no cats, no restriction. There is a reducer where the MP connects to the stock exhaust so you do not need a cat back exhaust. You connect to our stock exhaust which uses straight through muffler and reso's. The reduction down to 2 1/2 at that point should be no problem unless you plan to go over 300 wheel horses.
Result at this point in the upgrade: Huge gains, particularly in midrange performance. 60-100 mph times fell from 8.9 seconds in 90 degree weather to 7.9 in the same temperature conditions. That's a full second. In cooler weather (75-80 degrees), 60-100 mph drops to 7.5. Why use 60-100? Because it's repeatable, easier to control the variables run to run, to minimize the effect of traction problems and inconsistent launches, and to reduce the effect of heat soak and drive train shock when tuning.
But eliminating those two cats and opening up the system to straight through 3 inch up to the rear of the MP did result in a big increase in loudness and in droning, especially in the 2500 rpm range and when downshifting. This is with the stock muffler and both stock reso's still in place. This is consistent with my experience with other cars, especially turbo SAAB's.
Next step:
This may seem drastic but it proved effective -- add another reso. But where and which one? The ideal place to put an addtional reso would be between flanges in the 3 inch MP. This means cutting the MP, taking out enough of it to insert the reso and then welding or clamping the two sections back together.
Which resonator? A little research suggested that the Vibrant Ultra Quiet 3 inch reso would be just the right size. It is a straight through design with a lot of sound deadening material inside its oval outer shell. It's 17 inches in over all length, including excessively long inlet and outlet connections which can be shortened as needed.
The turboXS MP can be cut one inch behind its bend and again on inch before the flex joint which connects to the rear flange. The Vibrant Ultra Quiet Resonator's 3 inch inlet and outlets are, as stated, longer than needed and need to be shortened to fit the total over all length of the MP. Cut one inch off of each end. You can then assemble the parts loosely, loosely attach the MP to the flanges at each end. Rotate as necessary to get the flanges to match the bolt holes. Using a Magic Marker, Sharpie or similar marker place a mark across the MP and muffler inlet and then across the MP and muffler outlet, so you can line them up later and remove. After removal, line up the marks and either weld the three pieces back together (my method) or reassemble with stainless 3 inch muffler clamps. Then reinstall the now completed midpipe reso combo.
To finish off the completed system, I removed the 4 inch stock chrome exhaust tip and welded a 3 1/2 inch unrolled straight cut Magnaflow tip. No offense guys, but I'm going steath and this makes the car look less rice, is still bigger than the exhaust ,and since it's not rolled, it virtually disappears.
End result: The Vibrant Ultra Quiet Reso is aptly name. This restores the exhaust to stock volume and even eliminates the drone which the stock system had! Because the reso is a straight through design, the gains from the catless DP and MP are unchanged -- a full second drop or more in 60-100 mph time.