Porsche Boxster 986 history

Introduced in late 1996, the Porsche Boxster 986 is the first generation of this kind. A mid-engine two-seater roadster, based on the 1993 Boxster Concept was their first road vehicle to be originally designed as a roadster since the 550 Spyder. This first version had a 2.5-litre flat six-cylinder engine, which was then upgraded to a 2.7-litre engine. In the year 2000 and a new Boxster S variant was introduced with a 3.2-litre engine.

This was Porsche’s biggest volume seller from its introduction in 1996 until the production of the Cayenne sport utility vehicle in 2003.

Although it was generally produced at the former 928 facilities in Germany, it was also manufactured at a facility in Uusikaupunki, Finland under contract to Porsche. The 986 Boxster assembled in Finland has the letter “U” as the 11th character of the VIN instead of the “S” for the German assembled cars.

The Boxster’s name is derived from the word “boxer” and “roadster. “Boxer” refers to the vehicle’s flat or “boxer” engine, and the word “roadster”, indicates the vehicle’s two-seater capacity and convertible top.

The Porsche Boxster 986 was released ahead of the more expensive 911 (internally – 996) and has the same bonnet, front wings, headlights, interior, and engine architecture as that model.

Porsche exhaust and superb sports car sound

One of the essential features of a good sports car is the exhaust system and Porsche puts serious time and effort into crafting the ideal, pitch-perfect exhaust sound. The exhaust note is, synonymous with the brand itself and that’s why you can recognise a Porsche by its sound.

Porsche has designed fantastic sounding engines from the 1950s through to the current day. The “Porsche sound” is deep, full, strong, and sporty – a genuine sound of a sports car. That superb sports car sound is a direct result of its top-quality exhaust systems.

The audio design is conducted within the Weissach R&D Centre in a sound studio where Dr Bernhard Pfäff­lin and his team are working on their acoustical research. The team recorded sources of noise without reflections and isolate the sounds coming from the car using their acoustical camera.

First, they mix and produce the sounds digitally, like in a recording studio and then create or reverse engineer the perfect tone for each Porsche they work with. The sound is evaluated both objectively on noise-measuring tracks and subjectively on the road.

After the sound characteristics are defined, the exhaust system and its specifications are determined. Once all of that has been completed the exhaust system must go through a rigorous test programme – just like any other Porsche component. Following successful testing, the sports exhaust system is then fitted to the car to demonstrate its true capabilities. Everything described is done without increasing weight or hindering the car’s performance in any way.

Porsche Boxster exhaust upgrades

Although factory standard exhausts are great and do a solid job, there is always room for improvement and some personal preferences.

The options to upgrade the Porsche 986 exhaust are plenty as well as all Porsche versions before 2019 that have a naturally aspirated engine. One of the popular options is Porsche’s own ‘Tequipment’ upgrades as well as other well-known brand names specialised in exhaust systems. Also, recently we can see several smaller artisan-style businesses with low production but with custom-made and bespoke exhaust systems.

The important thing to keep in mind is that Catalytic converters (cats) are required for MOT on Porsches from 1992 onwards, so ‘de-catting’ a Porsche will create some issues during MOT. Another important part is the lambda sensor, which is a small regulating probe located on the car exhaust, between the exhaust manifold and the catalytic converter. The lambda probe will regulate the fuel amount by optimizing the air and fuel mix, which will also impact the harmful gas emissions rate which is also checked at the MOT. Regulating probe cable length will probably need to be adjusted after the upgrade.

Often exhaust manufacturers will provide these types of systems to retrofit:

–        Full system (replacing the exhausts from the manifold on the engine to the tips)

–       Exhaust manifolds (usually tuned to equal length and replace the bulky and restrictive factory parts)

–        Cat-back ( replacing the parts from the catalytic converters to the tips of the exhaust)

–       Final silencers or backbox (usually the last box right at the end of the exhaust).

The usual benefits of the exhaust upgrade would be a reduction in weight, an increase in noise and a potentially small uplift in power.

The highest cost is of course the full system and the lowest backbox change, due to the materials used and the time it takes to fit them. So, usually, the final choice of Porsche sports exhaust upgrade is mostly determined by budget and intended use. For example, the price of ‘Backboxes’ can range from around £1,000 to £3500. This also depends on the material it is made from and the type of Porsche it is fitted to.

The price for a Porsche 986 full sports exhaust system can be anywhere from £5000 to £15,000. The best practice to get the best optimization for performance is to re-map your car. This allows the ECU on the car to provide different flow rates and back pressures from the new exhaust. The new ‘map’ for the ECU can then be optimised to adjust the fuel/air mix and other important parameters to get better power and torque through the rev range.

When choosing the right exhaust for Porsche it is worth seeking advice from a business that has experience in working with specific Porsche models. It is sometimes seen in aftermarket exhausts to show a power reduction in back-to-back testing even though it was fitted to produce big power gains. Poorly made systems, that just don’t fit or have been poorly designed and are simply too loud or resonate at cruising speeds are something that should be avoided and sometimes leave us wondering if an upgrade of  Porsche sport exhaust is worth it.

Some of the Best Aftermarket Exhausts

For those who want to try something new and mix things up, there are plenty of great aftermarket exhausts to choose from. While some people prefer that signature Porsche sound, others may prefer the many aftermarket systems and variety of weird and wonderful options these have to offer. They have distinctive qualities and are worth looking into.

These are just some of the options that are available on the market.

Fabspeed Porsche Boxster 986 Maxflo Performance Exhaust System

Fabspeed is a producer of precision-crafted aftermarket parts including a full exhaust system. Although they have a variety of options, this example will apparently improve sports car sound and throttle response with an upgraded Maxflo exhaust muffler and inlet tubing.

This system will fit all Porsche Boxster 986 vehicles (1997-2004). It is constructed from high-quality 304 stainless steel, and offers ultimate performance gains and improved durability. It includes deluxe dual-style tips in your choice of finish, improves power and torque, and saves 30 lbs from the rear of the vehicle.

Fabspeed claims to use HJS Catalytic Converters which are imported catalytic converters made from some of the highest grade materials you can find in a catalytic converter. This yields high-performance gains and durability so it won’t deteriorate over time. The catalytic converter operating mode in this case consists of up to 93-95% of a straight pipe in most applications. The benefit is that you get the “straight pipe sound” while still being able to provide enough emissions scrubbing.

Dansk Sport Exhaust Super Sound with TUV

Dansk is a brand that offers various different combinations like cat bypass pipes or simply full exhaust systems. Their full sports exhaust system is made of stainless steel offering a fuller, more powerful sound. With that, you can choose from a few different tailpipes like exhaust stainless steel tailpipe SUPER SOUND or ORIGINAL LOOK.

The TUV version of the sport mufflers create amazing sound and performance while keeping within legal decibel limit. Dansk exhaust muffler is less restrictive than the factory system, reduces back pressure and produces more power. This exhaust muffler is for the more conservative drivers who want all the sound and performance without drawing all the attention to themself. It’s made with dual round outlets, from heavy-duty stainless steel, and supplied in a polished finish.

Dansk also offers various other exhaust accessories like manifold gasket, silencers, clamps, cats, extra gaskets, bypass pipes and manifold bolts.

Another popular option from Dansk is adding cat bypass pipes. These stainless steel pipes bypass the Boxster’s catalytic converter and reduce back pressure in the exhaust system. That simple change is all you need to get more performance and a better sound.

Design Tek SUPER SOUND Sports Exhaust Package for Porsche Boxster 986

This Porsche Boxster 986 stainless-steel exhaust system offers 304 stainless steel, higher hp and better torque, HJS sports catalysts, and 2″ tubing (50 mm) designed for max power.

It also includes a 2 x 200 cell sports cat, sports muffler and equal length headers. For the ultimate performance gains, ECU remap is recommended that will give BHP and torque that you can really feel and of course, a superb sports car sound will be delivered.

Borla Porsche Boxster 986 S 2000-04 Cat-Back

Borla developed a completely new high-quality stainless-steel package that is mandrel-bent. The emphasis of the system is reduced weight (less than half the weight of stock), as the exhaust is positioned significantly back at the very rear of this vehicle. The system will provide a better balance for those winding highways that these cars love. This part offers an impressive 263cfm more air than stock, which ensures the added performance.

The system provides a throaty and powerful sound, solid power gains and better mileage which makes it a perfect match for this exciting race-bred Porsche.

Topgear Porsche Boxster 986 Cat-Back with Chrome Tips

This is a (cat-back) exhaust for the Porsche Boxster 986, which also comes with chrome finish tailpipes. The system also includes a hand-fitted heat shield and is specifically designed to provide power gains and a smooth sports sound. The system consists of professionally mandrel bent and TIG welded stainless steel. It is a perfect upper-market, performance fit for the Porsche Boxster 986 and it includes all gaskets and bolts required to fit the exhaust system, unlike other systems.

TechArt

TechArt offers sport exhaust systems for nearly every Porsche model. Their product options span from whole sports exhaust systems and silencers to simple tips. The valve-controlled sport exhaust systems deftly control and adjust the sound according to the driver’s individual preferences.

TechArt’s tailpipes are particularly interesting, which come in black chrome, gloss chrome, or stainless steel. A sport exhaust system comes with two central tailpipes and a catalytic converter transmission type can be acquired with a special order as well.

These sport exhaust systems are also compatible with the series of tailpipes or can also be combined with TechArt sports tailpipes, which are made of titanium, carbon or stainless steel.