• 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. LostMarine's Avatar
        LostMarine -
        Click here to enlarge Originally Posted by George Smooth Click here to enlarge
        The system I got looses 28whp when open vs closed and I can clearly see why but I think the effort wasn't put it.
        ok, i dont feel so bad now whe i only lost 4hp. what exactly needs to happen to gain that, and hopefully more once its tuned? is it just an AFR thing? if it is, i would rather have it tuned for open and just run rich when closed.
      1. George Smooth's Avatar
        George Smooth -
        Click here to enlarge Originally Posted by hworang00 Click here to enlarge
        Sorry don't understand it...?
        I feel with the agency a better job could have been done in terms of power losses with the valves closed vs open. I will give them the benefit of the doubt as I haven't tested the looses with LTH yet.
      1. Sorena's Avatar
        Sorena -
        Click here to enlarge Originally Posted by George Smooth Click here to enlarge
        I have a review of the Agency unit in the M156 section in my build thread. Will be doing videos soon with the Lth on. It's a must have.
        Evolve system is well designed and as a company I think they are doing a great job with their r&d. The system I got looses 28whp when open vs closed and I can clearly see why but I think the effort wasn't put it.
        Man i heard some horrible stuff about Agency and their exhausts. Never been a fan of them, and they are made in Korea, right?
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by Sorena Click here to enlarge
        Man i heard some horrible stuff about Agency and their exhausts. Never been a fan of them, and they are made in Korea, right?
        People just say the stuff is cheap.
      1. George Smooth's Avatar
        George Smooth -
        Click here to enlarge Originally Posted by Sorena Click here to enlarge
        Man i heard some horrible stuff about Agency and their exhausts. Never been a fan of them, and they are made in Korea, right?
        The quality in my case is impeccable. Whoever does the welding is a master. We checked further in the exhaust at the internal side of the welds with a scope and the guy who welded the joints knows what he is doing. If you believe the the theory that its the same guy that makes them all its someone in Taiwan although all the companies are using different electrics so cannot confirm if the exhausts are all the same and each guy is doing his own electronics.
      1. George Smooth's Avatar
        George Smooth -
        Click here to enlarge Originally Posted by LostMarine Click here to enlarge
        ok, i dont feel so bad now whe i only lost 4hp. what exactly needs to happen to gain that, and hopefully more once its tuned? is it just an AFR thing? if it is, i would rather have it tuned for open and just run rich when closed.
        In my case its a back pressure problem as the gasses route a completely different way. Check the diagram on my build thread.
      1. Sorena's Avatar
        Sorena -
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        People just say the stuff is cheap.
        There was a guy in M5board, his Agency power exhaust had some cracked welds.
        Click here to enlarge Originally Posted by George Smooth Click here to enlarge
        The quality in my case is impeccable. Whoever does the welding is a master. We checked further in the exhaust at the internal side of the welds with a scope and the guy who welded the joints knows what he is doing. If you believe the the theory that its the same guy that makes them all its someone in Taiwan although all the companies are using different electrics so cannot confirm if the exhausts are all the same and each guy is doing his own electronics.
        Good to hear that you are satisfied. Click here to enlarge
      1. hworang00's Avatar
        hworang00 -
        Hmm...Sounds interesting...I would love to silence my car when I don't need all that power...but we'll have to see...
      1. George Smooth's Avatar
        George Smooth -
        Click here to enlarge Originally Posted by Sorena Click here to enlarge
        There was a guy in M5board, his Agency power exhaust had some cracked welds.


        Good to hear that you are satisfied. Click here to enlarge
        There where also alot of guys on M5board that vouched for Abid from ASR Engineering and look where it got me.Click here to enlarge
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by George Smooth Click here to enlarge
        There where also alot of guys on M5board that vouched for Abid from ASR Engineering and look where it got me.Click here to enlarge
        For the record, I questioned him and his credentials and Gustav banned me. True story...
      1. George Smooth's Avatar
        George Smooth -
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        For the record, I questioned him and his credentials and Gustav banned me. True story...
        I don't know anyone you haven't questioned Click here to enlarge true story? Click here to enlarge
      1. ERM324's Avatar
        ERM324 -
        wow just read this writeup for the first time, AWESOME R&D and writeup! Have never seen a company, at least for the S65 platform, put this much effort in their exhaust writeup - great job.

        I am very interested in this setup after reading it all, hearing the videos, seeing the pictures, and the BEST part is that there is no loss in power with the valves open/closed.

        In short, I have a full gintani catless exhaust with a catless xpipe with 4 resonators and their sport exhaust. The drone is getting pretty annoying with this setup, and I know it is characteristic of the rear section. I was thinking of swapping out the muffler for the stock muffler with the oem exhaust mod, but I dont like the look of it. And that leads me to this........I'm looking to throw this rear section on my car. Only thing I'm worried about it the rasp/drone with the catless xpipe (quad resonated) - do you guys have a video of this setup with a catless xpipe? I already have been through the dissappointment of ordering another rear section, throwing it on, and hating it and taking it off after 2 hours......this looks like a promising setup. If possible, can you post a vid of this with a catless setup if you have it? Also, can you post more pics of the tips up close? Im looking into the 90mm tips and will have them inside of a vorsteiner type II diffuser so I just want to get a better feel for how it looks. Thanks!
      1. Sorena's Avatar
        Sorena -
        Click here to enlarge Originally Posted by George Smooth Click here to enlarge
        There where also alot of guys on M5board that vouched for Abid from ASR Engineering and look where it got me.Click here to enlarge
        Click here to enlarge
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by George Smooth Click here to enlarge
        I don't know anyone you haven't questioned Click here to enlarge true story? Click here to enlarge
        Hah true, but I could have saved you money if Gustav didn't enable a crook...
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by ERM324 Click here to enlarge
        wow just read this writeup for the first time, AWESOME R&D and writeup! Have never seen a company, at least for the S65 platform, put this much effort in their exhaust writeup - great job.
        Yep, this is how you do a product release. Just excellent work from Evolve.
      1. Donbona's Avatar
        Donbona -
        These boys are really pushing the boat out when it comes to developing new products..... hopefully it wont be too long till they put this exhaust on my car. Click here to enlarge
      1. LostMarine's Avatar
        LostMarine -
        Click here to enlarge Originally Posted by Donbona Click here to enlarge
        These boys are really pushing the boat out when it comes to developing new products..... hopefully it wont be too long till they put this exhaust on my car. Click here to enlarge
        exhaust would be great, but im waiting on something for the front to push more air through that exhaust Click here to enlarge
      1. flipm3's Avatar
        flipm3 -
        Click here to enlarge Originally Posted by LostMarine Click here to enlarge
        exhaust would be great, but im waiting on something for the front to push more air through that exhaust Click here to enlarge
        Click here to enlargeClick here to enlarge
      1. Donbona's Avatar
        Donbona -
        Click here to enlarge Originally Posted by LostMarine Click here to enlarge
        exhaust would be great, but im waiting on something for the front to push more air through that exhaust Click here to enlarge
        Im already 1st in line Click here to enlarge
      1. LostMarine's Avatar
        LostMarine -
        Click here to enlarge Originally Posted by Donbona Click here to enlarge
        Im already 1st in line Click here to enlarge
        maybe 1st in the UK.... Click here to enlarge