XC90 V8 - Custom 3-Inch Stainless Mandrel-bent Magnaflow Exhaust

Full system from merge pipe back (factory 2.5" merge and 2-bolt flange replaced with larger 3" merge and v-band flange. Fully resonated. Stock cats are all present. Fully emissions legal. Completely self-fabricated (stainless MIG, 98/2 mix, Solar Flux instead of back purging).

[@rufixorg]

Birds in the background enjoyed that beautiful V8 sound too.

[@scottn2729]

Sounds awesome 👍

[@xyphur]

@@scottn2729 Thanks!

[@markbray2988]

Sounds awesome! Great job 👏🏻👏🏻👏🏻

[@xyphur]

Thanks Mark!

[@ellefields8878]

Just bought an 07 XC90 V8 last month. I know what mods I’m doing next. Where did you get the upper tail light. PS if you cut the power wire on your Yaw sensor and hook it up on to a toggle switch you can experience your XC in full beast mode, no traction control preventing you from sliding her sideways in the snow and gravel.

[@xyphur]

I modded the upper tails myself using LED strips cut from a roll. They're the densely spaced variety which aren't as common, but easily acquired on Amazon, etc. To run them, I'm using a PWM dimmer circuit (bought locally from an electronics supplier) with a relay wired into the circuit in a negative-switched configuration (the dimmer controls the negative side of the circuit), which accomplishes the ability of having running lights AND brake lights with a single strip of LEDs. The running lights mode is simply the circuit running through the PWM dimmer, and activating the brake lights energizes the relay, which bypasses the PWM dimmer to supply full 12v to the LEDs. The result is seamless and has been functioning for going on 2 years now I think. I've seen that yaw sensor mod before, I believe it was mentioned in one of the videos I watched of a guy who did an AWD swap into his C30. Intriguing, but I haven't gotten around to it. Mine is more of an asphalt queen after all (although it does see winter duty), being that it is lowered and stiffened up. The odd time I feel like playing in the snow, turning DSTC off has been sufficient. Apparently, the programming in the TCM and DEM will only allow the BCM to step in with ABS if you lift while you're countersteering and there's lateral acceleration being detected by the yaw sensor.... Solution: keep right foot planted :) That said, the next time I'm in a tinkering mood and don't have anything else on the to-do list, I might do this to see what effect it has on hard cornering in the dry. There have been a few occurrences where DSTC has thrown its hands in the air as if to say "I have no idea what you're up to but it doesn't feel right" and starts trying to step in cutting power and engaging brakes when I don't need or want it to. Very sketchy results typically follow. I've seen you over in the FB groups, will keep eyes peeled for your upcoming mods :) I can't recall which group I posted them to, but if you're looking for inspiration, there's some photos of this exhaust system while I was fabricating it and then after completion off the car. I'm Mark Wilson in the groups, in case you want to search for my posts.

[@ellefields8878]

That is super helpful, going to start shopping around for LEDs tonight. Was it easy pulling the lens off? Ce yet to get into the XC90 to deep seeing I only bought her a little over a month ago. Defiantly going to look for your pics of the install on that exhaust. I’d really like a little more grumble but not as much as my V70XC that’s straight up obnoxious. I hear a lot of people make mention of that Squirrleyness from traction control before. Read about some incidents at a track day, think it was in an S80. Everything was cool going into the turn but the moment he lifted his foot off the accelerator sit went sideways then backwards.

[@theKnightDesign]

Sounds soooo good. You’ve got a really clean XC90! How much do I need to pay you to do the upper taillight mod? Hahaha

[@ellefields8878]

I also noticed that, I want the LED brake lights on my XC90 too.

[@sinethembasibiya4327]

That Yamaha 4,2 engine 🔥🔥🔥

[@xyphur]

4.4 😉 ...but yes, fantastic engine!

[@heregoesmike]

Sounds wonderful. I have a couple questions. I notice that the reverse lights are on during the park light setting before start... also, the mirrors folded out after start, were both of these things done in VIDA? I'd love to have my mirrors fold and unfold when locking and unlocking...

[@xyphur]

I have a CFE+ that allows those functions to be added, plugs into the OBD port and hijacks the CAN network. Tons of additional functionality, way too much to list here. You want one though, trust me. You can pick one up from SwedeSolutions in NL. Not cheap, but worth it!

[@magnoooz]

Nice LED upper lights! Sounds fantastic!!! Damn she moves!!!

[@xyphur]

Thanks! She scoots not bad for how much of an asphalt yacht she is... haha She needs positive atmosphere in her intake, I may be toying with this idea... I need to figure out an electric power steering pump retrofit first so I can remove the factory pump and use that pulley location for.... "something else" ;)

[@magnoooz]

@@xyphur nice!!! Remote turbos would probably be easier 😂

[@xyphur]

@@magnoooz probably, but then the plumbing is a headache all its own. Plus, turbos will quiet down the exhaust note. I have nothing against turbos - I have a long-term goal of acquiring another SVX and doing a full turbo build on it - but the way I drive this thing, I'd rather have the instant torque and linear power of a supercharger. Of course, there's the whole tuning for boost aspect that I haven't even really fully explored in this application. It's currently got an off-the-shelf 'Stage 1' tune from D5T5 (using VDASH and a DiCE) but something tells me once boost becomes part of the equation, the factory ECU and software will be insufficient. If I were to go with my gut, I'd opt for a Haltech Elite, but then there's a whole CAN of worms to deal with (pun intended) given that everything on the car runs on CAN and probably more than a few communications between some essential modules are encrypted. It'll be interesting to figure out for sure!

[@andrewsharp8074]

@@xyphur Then the factory box and at least the angle drive will be unable to handle the power, especially off the line.

[@xyphur]

@@andrewsharp8074 there's a couple distinct solutions to that. 1) Build the auto internally (some beefier parts are available, check Sonnax's catalog for instance), along with TransGo's shift improvement kit for faster, more positive shifts (which cuts down on heat and friction/steel/band wear). The angle gear itself (and Haldex unit, for that matter) has proven itself capable of standing up to elevated power levels (built S60Rs have the same units and are pushing much more power through them than the V8 can muster), it's more the splined collar/sleeve that can potentially be the weak link, which has been addressed in a couple ways by others. Nitrided for added strength, and/or cross-pinned and welded to the angle gear input shaft (the half that the splines typically fail on, often stripping the splines on the angle-gear input shaft in the process, requiring a whole new unit), the trans output side's splines don't suffer the same failure that I've ever heard of. Conceivably, if one doesn't launch it from a dig like an idiot, or drive like a teenager all the time, it should hold up fine to some added power. We're not talking a ton here, granted, just enough to wake it up. The other option is to M66 swap it. The trans bolts up to the V8, being that the S60R/V70R 5-cyl was available with the same TF-80SC automatic as the V8, so bolt pattern is the same... the only thing that would need figuring out is the starter being in a different location between the 5-cyl and V8. Not necessarily 'simple' to do, but also not impossible, and nothing a bit of measuring, cutting, some fabrication, and some decent TIG skills couldn't solve. There is at least one person I know of who had already started work on an M66-swapped V8, and I think the trans bellhousing had been cut to make room for the V8 starter last I checked. I haven't followed up on it in a while, so I'm not sure what progress has been made since. All the other parts to make it work are readily available though (manual diesel XC90s in Europe = plenty of clutch quadrants + shifter mechanisms, trim, etc floating around) I'm on the fence about whether I want to keep the livability of an auto for a daily, or gain the driving engagement, shift speed, and lower drivetrain losses that a manual has. I'm not sure I would want to live with a manual again as a daily. I loved my Forester, but in traffic feathering an upgraded clutch gets old real quick. Decisions, decisions... :)

[@raycewhitman1625]

How was it fitting the R design rear lower bumper with a tow hitch? I have a hitch and want to install the same bumper with quad tips.. Any tips??? Also what should I go for an exhuast? Is there a whole kit out there where I dont need to buy seperate things and its just take the stock one out and put a aftermarket one in?