• Evolve Automotive E-Tronic performance valved exhaust system for the E92 / E90 / E92 M3 - Videos and dyno charts

      First of all, we would like to welcome our newest vendor Evolve Automotive! As an introduction to Evolve, here are the details on their valved exhaust system for the E9X M3. A valved exhaust for those unfamiliar with it means you can either open or close valves inside the exhaust to alter the sound. If you do not want to wake all your neighbors up for example when you decide a Vegas trip at 3 AM is absolutely necessary or happen to be driving by a police car this feature can sure comes in handy. The only other option for an electronic valved exhaust was really Kreissieg who costs and arm and a leg. The Evolve system is much more affordable, full details below.

      Evolve E-Tronic ĎPerformanceí Valve Exhaust Ė BMW E90 / E92 / E93 M3




      It's always hard to make an exhaust system which pleases everyone. Some like them loud, some not so. Even in our own case as enthusiasts we understand that there is no perfect exhaust system when it comes to sound level and noise.
      Exhaust note and sound level is something that is always a compromise on a fixed system. Sometimes you feel you itís not loud enough and other times too loud depending on what you have purchased.
      To have both in one package is the ultimate solution so you can choose.

      Creating a well engineered product is not so simple especially when you have so many variables such as back pressure, power output, sound volume and sound type in the equation.
      We have seen numerous times where the current systems lose power on the quiet setting with an acceptable sound level and then do not lose power on the louder setting but are simply too loud.
      We have gone as far as possible in our development and testing process for both power outputs, sound type and sound level.

      Our Objectives:

      Sound:

      - Noise level and type to be sporty, smooth and sophisticated with the valve closed
      - Minimal or zero drone with valve closed
      - Valve open noise to be epic without being too loud and something you can actually enjoy without being embarrassed.
      - Valve open noise to have a great pitch
      - The difference between the valves open and closed not to just be a difference in sound level but also sound type (very adventures from a design point)

      Engine Power Output:

      - Power output not to change with the valve open or closed (This is not easy!)
      - Dyno Testing as part of the development process
      - Back Pressure testing as part of the development process

      Installation / Servicing:

      - Easy of installation of the physical exhaust
      - Easy installation of the electronics which control the valve position
      - Valve operation to be electronic with a keyfob
      - Valve assembly to be easily removed in case of failure (will come with a lifetime warranty)
      - A good range of high quality tail pipes
      - Tail pipes to be individual and adjustable so individual stagger or length can be setup depending on individual taste and/or rear diffuser type

      The Development:

      The most difficult aspect of the development was to keep the power output of the S65 engine the same with the valves open or closed. For the evolve team it was unacceptable to lose any power when the valve is closed. It is very easy to make a valve based system where the back pressure dramatically increases with the valve closed. The most common method of creating a valve system is to put the valve on the end of one of the tail pipes on a regular fixed exhaust system.
      When this is done the cross sectional area of the perforated section reduces and creates a huge amount of back pressure. This is wrong.

      The Evolve E-Tronic uses two completely different paths when the valve is open or closed. We calculate and test different lengths and cross sectional areas of perforated tubes which take different paths.

      So how do we start the process?

      The first step is to fit pressure sensors across the entire stock BMW system. We fitted pressure sensors after the primary CAT, after the secondary CAT and just before the rear exhaust.
      We take a measurement at different RPMís and then during a dyno test.
      A completely free flow system is then fitted without CATís and a straight through rear silencer. Pressure testing is done again.
      Of course, we all know the results on the dyno of such a change and itís around +20-30hp / 30lb.ft torque.
      The aim is then to achieve the same power output but with a system with secondary CATís, mid silencers and a rear exhaust with two different paths for the exhaust gasses to exit (valve).

      Alot of time is taken at this stage to achieve the goal.

      Once this is achieved then comes a part which is in some ways even more difficult and time consuming Ė the noise type and pitch with both the valves open and closed while maintaining a zero power loss of the fully optimised system. The worst part is where we to make the valve rear silencer sound great with and without a primary DECAT and X Pipe!
      Before we even started this process we spoke to many people and what they think is the best noise level and what they want the exhaust to sound like.

      We already had alot of previous experience with the evolve X Pipe and fixed rear exhaust which sounded totally unique. Maybe a little too unique for the wider audience.


      Our Prototype:











      Dyno Testing:

      Independant Maha LPS 3000 measuring
      - wheel power (Radleistung)
      - run down losses (Schleppleistung)
      - calculated flywheel power (SAE corrected (Norm-Leistung) and uncorrected (Motorleistung))
      - pressure sensors along exhaust (1,2,3)
      - ignition timing (Zundung)
      - Lambda (OBD)
      - Inlet air temperature (T Ansaugluft Deg C)

      Note Ė Pressure sensors are placed before the secondary CAT, Before the X Pipe and before the rear exhaust

      Fuel Ė 100 Octane (Euro)
      Engine Management Ė Stock BMW

      1) Stock Rear Exhaust, Evolve X Pipe with 200CPi CATís, Resonators vs AA catless X-Pipe
      This dyno test is done to show the difference 200CPi CATís make. Basically very very little!


      2) Evolve E-Tronic Rear Exhaust + Evolve X Pipe with 200CPi CATís, Resonators
      Valves open vs valves closed


      Dyno Data of Valves Open with Evolve X Pipe


      Dyno Data with pressure tests with Valves Open and Evolve X Pipe


      Dyno Data of Valves Closed with Evolve X Pipe


      Dyno Data with pressure tests with Valves Closed and Evolve X Pipe


      3) Evolve E-Tronic Rear Exhaust + Factory X Pipe
      Valves open vs valves closed



      Dyno Data of Valves Open


      Dyno Data with pressure tests with Valves Open


      Dyno Data of Valves Closed


      Dyno Data with pressure tests with Valves Closed



      Analysis of results:

      1) Evolve E-Tronic Rear Exhaust + Evolve X Pipe with 200CPi CATís, Resonators

      The results clearly show there is no real measureable difference in engine power output with the valves open or closed.
      The pressure tests show a small increase in back pressure but this is not enough to make any real difference in engine power output. An approximate average increase of 0.10 Bar is seen through the exhaust system.

      2) Evolve E-Tronic Rear Exhaust + Factory X Pipe

      The results clearly show there is no real measureable difference in engine power output with the valves open or closed.
      The pressure tests show a small different in back pressure but this is not enough to make any real difference in engine power output. An approximate average increase of 0.15 Bar is seen through the exhaust system.

      Additionally, you can also see an average difference in pressure drop of approximate average of 0.5 Bar before the secondary CATís by deleting the primary CATís. This is why the power increase is so vast from a primary decat. Not just because of such a larger pressure drop but one that is so close to the engine.

      The main result is that we do not lose power with our valve exhaust on the quiet setting. To lose power the back pressure increase towards the rear end of the car needs to be very large.

      3) The dyno results show that our full system performs to the same level as any other X-Pipe/CAT/Rear Exhaust Setups with both valves open or closed.


      Images of pressure sensors locations:







      Additional information for readers to analyse results

      As you can see from the dyno data every run has information about ignition timing and lambda.
      We have shown what the stock ignition and lambda targets from the factory software below so you can have a better understanding of whatís going on.
      Please note these are Ďtargetsí and the actual end result has the effects of many variables.


      We hope the above information serves to be useful to the readers and shows the extent we go to when developing a product.

      Videos and images of tail pipes to follow.


      Prices:

      1) Rear Exhaust with Valves and Contoller with either tail pipe design - $3500
      (Includes connecting pipes to mate to stock X-Pipe)

      2) X Pipe with 200CPi High Flow CAT's + Resonators - $2750

      3) Full System - $6000

      Our valve system will fit any of the X Pipes on the market which mates to a stock rear silencer.

      I hope the prices seem reasonable. Given the competing products we are offering quite alot for the money when you consider valves, the highest quality tail pipes, proper engineering, high flow CAT's and resonators in the X Pipe.

      The initial adjustable tail pipes we will be offering are:

      1) 4 x 90mm Thin Rolled 20 Degree Angle Slash Cut Chromed (pictures show non chromed)

      2) 4 x 90mm 2.5mm Straight Cut Chromed

      We chose the 2.5mm staight cut because it is more visible from the rear.

      Images:

      4 x 90mm Thin Rolled 20 Degree Angle Slash Cut




      4 x 90mm 2.5mm Straight Cut Chromed





      Videos:

      Please note that the street mode is going to have an adjustment to make it quieter for the final production. The race setting will not change.







      This article was originally published in forum thread: Evolve Automotive E-Tronic performance valved exhaust system for the E92 / E90 / E92 M3 - Videos and dyno charts started by Sticky View original post
      Comments 82 Comments
      1. Puerto Rican 335d's Avatar
        Puerto Rican 335d -
        All that said, I could not read the dyno charts correctly. And by the way, I understand it there is minimal gain, correct me on this. Then it would be worthless to purchase. BUT, I got to give it to you its is SWEEETClick here to enlarge And anyway ANYTHING for the DIESEL guys!!!!Click here to enlarge
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by Puerto Rican 335d Click here to enlarge
        All that said, I could not read the dyno charts correctly. And by the way, I understand it there is minimal gain, correct me on this. Then it would be worthless to purchase. BUT, I got to give it to you its is SWEEETClick here to enlarge And anyway ANYTHING for the DIESEL guys!!!!Click here to enlarge
        There are substantial gains actually, this may help you read a MAHA dyno: http://www.bimmerboost.com/content.p...rivetrain-loss

        I think I want this rear section as I want a valved exhaust. This may be the solution to the problem of my car setting off alarms as I drive by.
      1. LostMarine's Avatar
        LostMarine -
        Click here to enlarge Originally Posted by Puerto Rican 335d Click here to enlarge
        All that said, I could not read the dyno charts correctly. And by the way, I understand it there is minimal gain, correct me on this. Then it would be worthless to purchase. BUT, I got to give it to you its is SWEEETClick here to enlarge And anyway ANYTHING for the DIESEL guys!!!!Click here to enlarge
        no, what is being shown is that the power gains from goin to aftermarket exhaust are there, right in line with any other exhaust. BUT valve open or closed doesnt change the power, just the sound level.. basically
      1. klipseracer's Avatar
        klipseracer -
        Makes me want an E90 M3.
      1. leo985i's Avatar
        leo985i -
        That is one hell of a job you guys did. Very amazing indeed. Congrats!
      1. leo985i's Avatar
        leo985i -
        @Sticky Nothing wrong with setting alarms as you drive, I wish I could have that Epic sound myself, not going to happen without an S65 though - IMPRESSIVE sound indeed, my favorite V8 for sure.
      1. fast4door's Avatar
        fast4door -
        that thing sounds sick..
      1. Sticky's Avatar
        Sticky -
        I want this exhaust...
      1. inlineS54B32's Avatar
        inlineS54B32 -
        I am still waiting on a guy in Chicago (@Sticky - has he been active on the boards?) - but if he doesn't come through, I am DEFINITELY going to get this system. This is awesome. Gains are awesome, sounds is awesome - and the ability to "shut it up" when I am driving my Mom to church (can't really think of a real world scenario - so I made this one up) is pretty cool too. Click here to enlargeCheers.
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by inlineS54B32 Click here to enlarge
        I am still waiting on a guy in Chicago (@Sticky - has he been active on the boards?)
        What guy?
      1. flipm3's Avatar
        flipm3 -
        Welcome to GermanBoost as supporting vendor! There is no doubt that the forums will gain a wealth of information with the vast knowledge and experience you have.I have mentioned it several times already, but the development of both your E60 M5 and E9X M3 E-Tronic Exhaust is a true testament to your level of honest and purposeful engineering. There is no doubt that this dedication will be rewarded with an even more expanding client base.Now if only I wasn't giving you guys all the pennies in my piggy bank to mod the E46 M3, then I could afford the best exhaust for the E90 M3 by you guys, haha.
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by flipm3 Click here to enlarge
        Welcome to GermanBoost as supporting vendor! There is no doubt that the forums will gain a wealth of information with the vast knowledge and experience you have.I have mentioned it several times already, but the development of both your E60 M5 and E9X M3 E-Tronic Exhaust is a true testament to your level of honest and purposeful engineering. There is no doubt that this dedication will be rewarded with an even more expanding client base.Now if only I wasn't giving you guys all the pennies in my piggy bank to mod the E46 M3, then I could afford the best exhaust for the E90 M3 by you guys, haha.
        Awesome post.

        What are you doing to your E46? You got the Evolve tune right?
      1. Yukohama's Avatar
        Yukohama -
        about time someone came out with one, well done guys!
      1. evolve's Avatar
        evolve -
        Hi Guys,well, finally on board after being a guest vendor for quite some time.glad you appreciate all of the testing.If you look closer at the results there is more information there about what a complete decat does vs high effficiency 200 CELL cats.The systems are all being produced and will be ready late January 2012.If anyone wants me to make a quick summary of the above rather than read the whole thing just say so.
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by evolve Click here to enlarge
        Hi Guys,well, finally on board after being a guest vendor for quite some time.glad you appreciate all of the testing.If you look closer at the results there is more information there about what a complete decat does vs high effficiency 200 CELL cats.The systems are all being produced and will be ready late January 2012.If anyone wants me to make a quick summary of the above rather than read the whole thing just say so.
        Usually vendors don't throw this much content at once. Not everyone reads all of it even though they should!
      1. 0-60Motorsports's Avatar
        0-60Motorsports -
        Welcome to the forums as a FULL Vendor EVOLVE. That exhaust is awesome. Now were all waiting on an E46 M3 version soon Click here to enlarge
      1. disruptv's Avatar
        disruptv -
        Click here to enlarge Originally Posted by evolve Click here to enlarge
        Hi Guys,well, finally on board after being a guest vendor for quite some time.glad you appreciate all of the testing.If you look closer at the results there is more information there about what a complete decat does vs high effficiency 200 CELL cats.The systems are all being produced and will be ready late January 2012.If anyone wants me to make a quick summary of the above rather than read the whole thing just say so.
        welcome aboard

        Will this throw off a CEL withthe 200 cell cats? Also, how many rwhp gain are you expecting with the full system (with 200cell cats) vs stock?

        Thanks
      1. Puerto Rican 335d's Avatar
        Puerto Rican 335d -
        To everyone I was finally able to read and HERE the car WHOAAA!!! I love the sound but the price has me thinking, @Chris whatever happened to your system, and Also is EVOLVE going to have one the "D" guys in the future?
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by Puerto Rican 335d Click here to enlarge
        To everyone I was finally able to read and HERE the car WHOAAA!!! I love the sound but the price has me thinking, @Chris whatever happened to your system, and Also is EVOLVE going to have one the "D" guys in the future?
        No diesel plans for this exhaust.
      1. Puerto Rican 335d's Avatar
        Puerto Rican 335d -
        @Sticky damn it to hell, you ruined my wet dream, LOL. BTW let me know when you come down here, I will be posting photos of my car soon on the site. or PM me and I'll send you a photo of the car via my Sprint phone ok