for NA exhaust tuning, a larger exhaust might "free up" some additional
power, but we're talking small amounts here. a VERY GOOD exhaust system
on a 200hp car might free up 15-20hp. im taking into consideration my
alfa here where the stock exhaust is already very well designed.
so dont expect power gains from exhaust tuning like u would get for a
turbo car.
what ur really doing in modding ur exhaust is "move" the power curve. a
more free-flowing exhaust will move the peak power further up the rpm
range. and vice versa for a more restrictive exhaust. so u tune ur car
for the rev range where u do most of ur driving. if ur a racer, low-end
torque below 3000rpm is useless to u. if all u do is day-to-day driving,
u have no use for power above 5000rpm. there are no free lunches.
there is also a range of exhaust diameters where the engine is effective.
too small and it will 'choke' the exhaust gas flow and the engine will
lose power. too large and you will lose so much back pressure you have
virtually no useful torque (essentially u have moved the power so far up
the rev range its useless to you).
all this talk about 4-2-1, s-flow, bullets are inconsequential. what u
gotta know is how large ur piping diameter is. a 2.5" s-flow muffler will
likely flow better than a 2.2" straight-flow muffler. a bullet is merely
a middle muffler. its a perforated pipe with an expansion chamber and
some insulation in it. the shape of the "bullet" isnt as important as the
piping size inside and the quality of the build.
a "larger/longer" muffler will always be quieter than a shorter/smaller
one.
all else being equal, a perforated pipe (like inside a muffler) will
generate slightly more back pressure (turbulent flow and all that) than a
smooth pipe.
all else being equal, a s-flow pipe will generate more back pressure than
a straight-flow pipe.
u can tune exhaust using any combination of the above. i can tune more
back pressure into a system using a simple smaller diameter straight-flow
pipe versus a more complex (and expensive) s-flow pipe.
the closer the changes are made to the engine, the more impact it will
have on back pressure. a free-flow cat (or a de-cat for that matter) will
have more impact on freeing up flow than a larger rear muffler which is
further downstream from the engine, all else being equal.
just because an "s-flow muffler" worked for one car doesnt mean it will
get the same results for ur car. exhaust tuning is highly engine
dependent. while the above "rules of thumb" apply in general, a lot of
experimentation is required.
and butt dynos dont cut it. u will always feel a gain cos u paid money
for it. if u really want to know what ur car is doing, put it on the dyno
before and after.