In the performance ocean of various types, sizes and shapes of aftermarket exhaust systems few stand out at the top of the food chain. Their position is determined not only by their popularity or horsepower gain, but also their pedigree. There are only few domestic brand name exhaust systems that I can classify as those. Since the beginning of the Subaru enthusiasts’ boom, few companies decided to make complete exhaust systems for these amazing cars. Among those companies is DC Sports. Recently acquired by an aftermarket dominator, Advanced Engine Management (AEM), DC Sports expanded their product line to include Subaru exhaust systems, uppipes, downpipes and turbo manifolds.

i-Club parts review department (or simply put me) was fortunate enough to get our hands on these fresh parts. Unfortunately, the downpipes are still in the final stages of the development and production, so we’ll review it later on.

EXHAUST SYSTEM:

When UPS dropped off the exhaust box, I though it was a mistake since the packaging was way too small to be your average exhaust box. I decided to open it prior to signing for it to make sure it was the right part. Sure enough it was. Upon inspection, I noticed that the DC Sports exhaust system is 3-piece design: muffler and 2-piece midpipe. It is definitely unusual, but very useful I think. Looking closer, you can see that the front ½ of the midpipe has a nice tubular resonator and a flex joint. Yes, a flex joint. To some it may seem unimportant, but with dozens of various up and downpipes, fitment could become an issue and having a flex joint really helps. The system is made from T-304 stainless steel and is 3” inches in diameter with very nice minimum mandrel bends. The muffler is a nice robotically welded T-304 stainless steel piece with a stylish straight-cut four-inch tip proudly wearing DC Sports logo. Note that the muffler sits straight and not tilted to one side like most big muffler systems. It states the true nature of the Impreza that it “hangs” on but yet does not scream it in your face, very good feature for a muffler of this size. Everything you need to install the DC Sports system was in the box so you won’t have to run around looking for bolts and gaskets. Retail price on this system is $852.09 and it is available for both WRX and WRX STi through many DC Sports authorized dealers. To find a dealer near you, please go here: http://www.dcsports.com/dealer_finder.asp.

Installation of the system went very smooth, as expected. The system bolted nicely to the stock downpipe without any issues. The flex joint surely helped bolting it to the stock USDM downpipe that sits at a slightly different angle than regular WRX downpipes. Comparing to the stock STi exhaust system, DC Sports system is not only larger diameter, higher flowing and better looking, but it is also lighter by nearly 10lbs.

Upon staring the car, the car burbled nicely, inviting me to take it for a spin. After waiting for a few minutes to let the gaskets heat up to insure that there are no leaks, I went for a spin. DC Sports exhaust system is surprisingly quiet considering the pipe diameter and less restrictive muffler and the resonator. Turbo spool up was improved as well as the top end performance. Even at wide open throttle, the muffler did not emit the raspy “N1-ish” sounds that some other systems tend to make. Slight smell of “muffler breaking in” was noticeable, but that is typical of all new systems. It went away after a day of driving. DC Sports packaged each piece of the exhaust system in a plastic bag, so no peanuts were hurt/burn during this test. The exhaust sound did become more apparent after few hundred miles, but I would still qualify it as being reasonably quiet. On a scale of 1 though 5 of loudness, I would give it a solid 3, 1 being stock and 5 being Apex N1. Having driven close to 100 Subaru’s both stock and modified, I can safely estimate the power increase of about 15-20 horsepower. Solid dyno numbers will be available after I get my hands on the DC Sports downpipe in the near future and test everything on the Dynamic Dyno.

All in all, I was impressed with DC Sports exhaust system. It is a good addition to the list of available exhaust systems for USDM Impreza WRXs and STi’s. I am sure this system would be popular among those whore are looking for maximum performance with less aggressive style. Thank you for a great product, DC Sports. Thank you LIC Motorsports (www.licmotorsports.com) for helping us with the install and thank you, Kevin for providing us with a brand new STi.

Please stay tuned for part 2 of this review in which we will report on the DC Sports turbo manifold and uppipe.

Could you please post more pics of the exhaust on the STi. I am looking for an exhaust for my STi and still have not made up my mind on which one I want. I want something that has a straight design (not angled) and the DC Sports exhaust looks nice. How would you compare this exhaust to the popular Greddy EVO1 or 2. Thanks.

What angle would you like to see? I have lots of pics.

How does it compare to GReddy? Good question.

IMHO, soundwise, they are about the same. DC Sports has a bit higher tone to it and Greddy sounds lower/deeper. GReddy uses larger diameter muffler. That is what changes the exhaust note.

Quality wise, they are both superb units. DC is full stainless and GReddy has mild steel piping. Looks wise, since DC has a smaller muffler, it is harder to see it from behind.

I do like the 3-peice design like I said earlier.

Both are great systems and their price points are about the same. It just a matter of style, I think.

Hmmm, How to get a sound clip? I'll see if I can make this happen.
Beautiful product with great performance gains.

-Kevin

Kev, give us an update on how you like this. Be a little bit more specific, please.

Is the turbo ported on that or my real question. Any boost creep with it???

What angle would you like to see? I have lots of pics.

How does it compare to GReddy? Good question.

IMHO, soundwise, they are about the same. DC Sports has a bit higher tone to it and Greddy sounds lower/deeper. GReddy uses larger diameter muffler. That is what changes the exhaust note.

Quality wise, they are both superb units. DC is full stainless and GReddy has mild steel piping. Looks wise, since DC has a smaller muffler, it is harder to see it from behind.

I do like the 3-peice design like I said earlier.

Both are great systems and their price points are about the same. It just a matter of style, I think.

Maybe some shots from the back (but further), from the side... here are the things I want to know (and that is why I asked for more pics).

1) It looks to me that the exhaust is NOT angles, am I correct?

2) How much space is there between the exhaust tip and the lower part of the rear bumper? I don't like it when its too close coz it burns the bumper, etc.

3) How much does the tip stick out? I don't like it when the tip is inside the rear bumper (or falls short).

4) Were there ANY fitment problems like there is for the Greddy EVO2? Such as piping rubbing with the rear suspension/body of car, tip rubbing on rear bumper, etc.?

5) Is it a BOLT-ON system? No modifications necessary right?

6) I have never bought a DC Sports product so I don't know much about their quality and stuff... is this a Japanese company (japanese manufactured products) or domestic?

7) This might sound stupid but... what difference does it make that the system is a 3-piece or a 2-piece?

BTW, this is a cat-back system right? Hehehehe... was not sure. Some sound clips would be cool too. I definitely love the looks (looks very similar to the EVO2) so I might consider this exhaust! Thanks!!!

Is the turbo ported on that or my real question. Any boost creep with it???

With the Exhaust alone, no porting/polishing of the turbo is necessary.
When I added an aftermarket downpipe, I had the turbo ported and polished to avoid boost creep.



Maybe some shots from the back (but further), from the side... here are the things I want to know (and that is why I asked for more pics).

1) It looks to me that the exhaust is NOT angles, am I correct?

-you are correct, NOT angles

2) How much space is there between the exhaust tip and the lower part of the rear bumper? I don't like it when its too close coz it burns the bumper, etc.

-If you look at the second picture in the original post, I installed some Cusco hardened exhaust hangers. I have experienced no discoloration running catless and shooting large fireballs on the track with racegas.

3) How much does the tip stick out? I don't like it when the tip is inside the rear bumper (or falls short).

-I think the tip is just right, but you will have to wait for new pics to be the judge of that.

4) Were there ANY fitment problems like there is for the Greddy EVO2? Such as piping rubbing with the rear suspension/body of car, tip rubbing on rear bumper, etc.?

-The fitment is excellent, no rubbing and the exhaust tucks up nice and high. I have it lowered with Cusco Zero 2R's and have not scraped once.

5) Is it a BOLT-ON system? No modifications necessary right?

-Yes, 3 piece bolt on Cat-back exhaust.

6) I have never bought a DC Sports product so I don't know much about their quality and stuff... is this a Japanese company (japanese manufactured products) or domestic?

DC Sports (now owned by AEM) is an American company that has produced some of the best Headers and Exhaust for Hondas and imports for many years.

7) This might sound stupid but... what difference does it make that the system is a 3-piece or a 2-piece?

-3 piece systems have a little more play for fitment with varying downpipes. Each joint has a little play that can be adjusted for the best fit. The flex joint in the system also adds to this. The 3 piece system is less to ship because it the box is smaller than a two piece system.

BTW, this is a cat-back system right? Hehehehe... was not sure. Some sound clips would be cool too. I definitely love the looks (looks very similar to the EVO2) so I might consider this exhaust! Thanks!!!

-Yes, catback. I will try to get a sound clip up soon with some side angle shots. The exhaust note will be a bit off as I have the DC Sports Stainless Race headers on the car as well. They add a raspy racecar sound to the system.

-Hope this helps some, Kevin.

2) How much space is there between the exhaust tip and the lower part of the rear bumper? I don't like it when its too close coz it burns the bumper, etc.

-If you look at the second picture in the original post, I installed some Cusco hardened exhaust hangers. I have experienced no discoloration running catless and shooting large fireballs on the track with racegas.


If you use stock hangers, what would be the space between the tip and the bumper? Would I need to buy kartboy long hangers so that the space is safe enough to prevent burning/discoloration? Thanks so much for the reply... I am more and more leaning towards this exhaust. The only thing that is worrying me is the space between the tip and the rear bumper. If using stock exhaust there's atleast 1/2 inch then I think that's a good spacing. Did you installed Cusco hardened hangers so that the exhaust is more stiff or because you wanted it to hang lower?

CUSCO hangers actually sit higher. Stock hangers would make it sit closer to the bumper. You can keep stock hangers or get longer kartboys.

CUSCO hangers actually sit higher. Stock hangers would make it sit closer to the bumper. You can keep stock hangers or get longer kartboys.

Cusco hangers = sit higher = closer to bumper?
Stock hangers = closer to bumper... which sits closer to the bumper, the Cusco ones or the stock ones? Will it burn the bumper if I use the stock ones?

Here's a couple more answers to your questions...

1) It looks to me that the exhaust is NOT angles, am I correct?

- The muffler is not angled down. We did this thinking that the WRX will be for both street and off-road use. With our muffler tucked under the bumber and not angled down, we are able to create great ground clearance for all types of terrain.


2) How much space is there between the exhaust tip and the lower part of the rear bumper? I don't like it when its too close coz it burns the bumper, etc.

- The exhaust tip is approximately half an inch from the bumper.


3) How much does the tip stick out? I don't like it when the tip is inside the rear bumper (or falls short).

- Our tip sticks out approximately half an inch past the bumber.


4) Were there ANY fitment problems like there is for the Greddy EVO2? Such as piping rubbing with the rear suspension/body of car, tip rubbing on rear bumper, etc.?

- We have not had any problems nor complaints with the fitment of the exhaust system.


5) Is it a BOLT-ON system? No modifications necessary right?

- This is a 100% bolt-on system. No modifications are necessary.


6) I have never bought a DC Sports product so I don't know much about their quality and stuff... is this a Japanese company (japanese manufactured products) or domestic?

- Our products are 100% U.S. made.


7) This might sound stupid but... what difference does it make that the system is a 3-piece or a 2-piece?

- There is no performance difference with the number of pieces to a system. The 3-piece system just makes for a more convenient, easier installation.

Cusco hangers = sit higher = closer to bumper?
Stock hangers = closer to bumper... which sits closer to the bumper, the Cusco ones or the stock ones? Will it burn the bumper if I use the stock ones?

CUSCO hangers make the muffler sit closer to the bumper.
Stock hangers make the muffler sit lower/further away from the bumper.

One more question... and sorry if I ask too much but I just wanna make sure that this is it!
Does the exhaust sound louder when at idle, low rpms, or high rpms?

One more question... and sorry if I ask too much but I just wanna make sure that this is it!
Does the exhaust sound louder when at idle, low rpms, or high rpms?

Compared to stock, the exhaust is always louder. At lower RPM's, the exhaust is lower in tone and pulsing like a classic Subaru Boxer engine. The higher the RPM, the higher pitch the exhaust note, and louder it gets.

The thing to remember, lower tones resonate farther.

In my experience with exhausts for subaru's, the DC sports is in the middle of the sound category. Not too loud, not too soft, but just right. If you add their race headers to the mix, things get really loud.

Hope this helps and good luck.

-Kevin

Can you guys please post more pics? What about the video clip? Thanks... I'll be stopping by my local shop this Wednesday to ask about the DC Sport system. BTW, I heard a Stromung catback today and I was wondering if the DC Sport was louder or quieter... the Stromung sounded really deep and nice... thanks!!!

I have one on my wife's WRX wagon along with the DC header. It sounds quite good to me and fitment is typical DC Sports - great! I have DC exhausts and headers on both of my other cars (Honda and Acura) and have loved them for years. This is why I waited for the DC exhaust.

Unfortunately, I put the exhaust on while the wife was out of town and it IS basically her car. For her, it is a bit loud at idle and low speed. It is not at all intrusive on highway cruise until you get on the gas. Since it is her daily driver I've decided to put a Prodrive muffler on as a compromise.

The DC exhaust is for sale, but if I don't get any reasonable offers I'll probably keep it for the planned STi in the spring to replace my daily driver Civic Si. I've posted it on the for sale forum.

I have one on my wife's WRX wagon along with the DC header. It sounds quite good to me and fitment is typical DC Sports - great! I have DC exhausts and headers on both of my other cars (Honda and Acura) and have loved them for years. This is why I waited for the DC exhaust.

Unfortunately, I put the exhaust on while the wife was out of town and it IS basically her car. For her, it is a bit loud at idle and low speed. It is not at all intrusive on highway cruise until you get on the gas. Since it is her daily driver I've decided to put a Prodrive muffler on as a compromise.

The DC exhaust is for sale, but if I don't get any reasonable offers I'll probably keep it for the planned STi in the spring to replace my daily driver Civic Si. I've posted it on the for sale forum.

Thanks for the input... I hope you get the STi in the Spring, it is THE **** car!

Yesterday afternoon I went to my local shop to order my DC Sports exhaust system for my STi... it will be installed on Saturday morning if everything goes as expected. I just wanted to ask is there something I should be careful about once they are done with the installation? Like things I should notice to make sure they installed it properly? Is there anything I should tell them to be careful about BEFORE they install it? Also, by installing this cat-back, will it affect the boost of the turbo or the ECU in anyway? Thanks! I can't wait to get the exhaust!

As far as the the cat back exhaust, nothing tricky about it. I would suggest some hardened exhaust mounts. The same size as stock, longer, shorter, it just needs to be solid.

-Kevin

As far as the the cat back exhaust, nothing tricky about it. I would suggest some hardened exhaust mounts. The same size as stock, longer, shorter, it just needs to be solid.

-Kevin

Why do we need harder exhaust mounts if the DC Sports is suppose to be 10lbs lighter? Why are the stock ones not good enough? Should I be getting kartboy extra long hangers? :)

And I forgot to ask...

WILL THIS EXHAUST SYSTEM FIT A 2005 STI?????????????????????????????????
I CALLED DC SPORTS AND THEY SAY THEY HAVE NOT VERIFIED IT ON A 2005 SO THEY ARE NOT SURE :( !!! WILL IT FIT??????????????

The hardened hangers are nice cuz the DC exhaust site closer to the bumper than the factory oem does. All exhausts, even the factory stuff can bouce a little over rough terrain. As I hashed out earlier in this thread, I have had no issues with any burns or discoloration of my bumper. My car is catless and shoots healthy fireballs regularly.

You can use the factory hangers and you will see that they do work, but I prefer my exhaust to be mounted solid.

It should fit a 05 as the only change from 04 was some blace paint on the muffler. We bolted a Carbon Ti on a 05 with no issues.

-Kevin

Just came back from the shop and the DC Sports cat-back is installed on my 05 STi! Here's what I think of it...

Pros:
- They told me there was no fitment problems... perfect fit I guess.
- There is enough space between the tip and the rear bumper.
- The tip sticks out just enough.
- Nice sound, even at low RPMs.


Cons:
- Muffler seems to be a little crooked... or the hole on the bottom part of the tip is not centered.
- Muffler looks very small.

Question... will the sound remain the same or change with use? Louder? Quieter? Thanks! Anything I should be careful or attentive about?

Brian

The location of the hole should not concer you. I bet it is for the optional silencer or the drain hole for collected water. No biggie. ;)

Muffler is small, but as I explained there is a reason for that. You won't scrape it. You won't attract extra attention.

And, to answer your question, please read my review post. ;) There is an answer there.

There's one thing that is kinda bothering me although I know its very minimal... if I stare at my exhaust from the back and look straight at it, the exhaust is not 100% straigh, the muffler is a little tilted to the driver's side... but barely noticeable. Hehehehehehe... anyways, now I am always looking for an excuse to drive my car just so I can enjoy my new exhaust! Great exhaust DC Sports!

I installed the exhaust on Friday and up till now I can still smell something burning although not as dominant as the first couple days (without playing with the DCCD until today). Today I was playing with the DCCD controller and I noticed that the burnt smell became stronger once I got home... is there something wrong? Should I be worried?

what else type of exhaust do you guys have??? i'm a chick looking for an exhaust for my sti but still didn't choose what type of exhaust i want. any sugguestions???

Do not lock the DCCD unless you are a loose surface, ie, gravel, snow sand

Do not lock the DCCD unless you are a loose surface, ie, gravel, snow sand

I didn't put the DCCD in "lock" but rather in the "35/65" mode...

what else type of exhaust do you guys have??? i'm a chick looking for an exhaust for my sti but still didn't choose what type of exhaust i want. any sugguestions???

A couple weeks ago I was in the same position as you are right now. I really wanted a cat-back exhaust but wasn't sure which one to get. I knew that I didn't want my exhaust to be angled and there were some that I just didn't like because of how they looked... nor did I wanted something that was going to be too loud. I was almost sure that I wanted the Greddy EVO2 when I did more research and discovered that many people had encountered problems with fitment, tip being too close to the bumper which were all problems I didn't wanted to deal with. Then a couple days after I saw this thread displaying the new DC Sports exhaust for the STi. At first I was skeptical cause I have never owned a DC Sports product and I kinda wanted a Japanese exhaust for my STi. But after asking the tons of questions I did at the beginning of this thread I realized that this exhaust was VERY similar to the Greddy EVO (just a smaller canister) but without all the other fitment problems and stuff I had heard from some of the owners of the EVO2. I finally decided to go with this exhaust and I must say that I looooooove it. It sounds really nice and deep at low and high rpms (not too silent but not crazy loud either), but probably most noticeable at low rpms coz at high rpms the engine is kinda loud. The fitment seems to be perfect and the tip is just exactly where it should be, not too close to the rear bumper nor falling too short either. It also looks really subtle, since the tip and canister are relatively small but it looks nice as everything is stainless steel. I would definitely suggest you to get the DC Sports exhaust... not to mention that I paid $530 with installation in LA (and yes it was brand new). Good luck with your purchase!

There's one thing that is kinda bothering me although I know its very minimal... if I stare at my exhaust from the back and look straight at it, the exhaust is not 100% straigh, the muffler is a little tilted to the driver's side...

Can someone please confirm this? The more I look at it the more angled it looks... the canister is definitely not straight (parallel to the side body). Please help!

Still have one of these for sale... make an offer!

Can someone please confirm this? The more I look at it the more angled it looks... the canister is definitely not straight (parallel to the side body). Please help!

Can you take a couple of photos of it for me? I'll follow up with the DC guys to confirm it.

Which part of the muffler is tilted to the driver's side? The front of the muffler (front is where most people think is the back, the front is actually where the muffler bend is at, the end is where the tip is at) or the rear of the muffler?

Can you take a couple of photos of it for me? I'll follow up with the DC guys to confirm it.

Which part of the muffler is tilted to the driver's side? The front of the muffler (front is where most people think is the back, the front is actually where the muffler bend is at, the end is where the tip is at) or the rear of the muffler?

The muffler itself is straight... but its not parallel to the side of the car. If you look at it straight from the back (by standing in the middle of the car), you will notice that there is a slight angle (I'll say maybe 5-10 degrees MAX). The "front" of the muffler tilts a little to the left (driver's side) and the "end" of the muffler is slightly to the center (right). I'll take some pics this weekend and I'll post them. Not sure if you will be able to see this minimal thing... maybe I am just too picky :). Oh and I forgot to mention that the top where it displays the "DC Sports" logo is a little scratched... and the tip is not 100% round... kinda like maybe it was dropped and it got a little messed up. Barely noticeable too though so I can live with that :).

anyone know how loud this is compared to the borla hush, Im looking for a nice catback that is quiet but with a single tip and the flex section is nice to have since my new downpipe doesnt have one...

anyone know how loud this is compared to the borla hush, Im looking for a nice catback that is quiet but with a single tip and the flex section is nice to have since my new downpipe doesnt have one...

i've only heard one...on kevins not stock STi.

It's louder than the hush. But it's not like an N1 or HKS or something like that were you get a head ache or get pissed and drop kick your exhaust. .

I think Alex's rating of 3 is accurate..where I'd put the hush at a 2.

I am either getting DC or borla...only reason I'd get borla is that I am partial to the twin tip look. Otherwise I'd get DC. Coming from the honda world as well as having "near" family work for DC I like their stuff. Great fit. Great R&D. Great workmanship. And with AEM running the show now it can only get better. AEM is hands down in my opinion the best parts manufacturer in the street tuner world. Them and K&N. They both spend a tramendous amount of time in lidigation making things legal for us.

I put AEM on top because they have such a huge market share with honda/acura and they obviously make up a tramendous percentage of street tuners world wide.


So yeah...in short...it's not to loud. Open it up..it gets louder. Nice low tone. Great exhaust from what I've seen of it.

hrmmm maybe ill have to get the dc then, my 05 has the single tip so im going to try sticking with that. I liked the borla because its quiet and if the dc is only slightly louder I can deal with it.

hrmmm maybe ill have to get the dc then, my 05 has the single tip so im going to try sticking with that. I liked the borla because its quiet and if the dc is only slightly louder I can deal with it.

The DC is a great choice. It makes your car sound deep and mean... not loud and annoying. It also looks really subtle (tip is not that big), compared to the more "aggressive" looks of other aftermarket exhausts.

any possibilities of anyone with this getting a sound clip of it? I might go a buy it on friday but I have to make sure its not good be too loud for me.

any possibilities of anyone with this getting a sound clip of it? I might go a buy it on friday but I have to make sure its not good be too loud for me.

I'll post some pics and a sound clip tomorrow if I can.

any possibilities of anyone with this getting a sound clip of it? I might go a buy it on friday but I have to make sure its not good be too loud for me.

I'll post some pics tomorrow... but I can't post clips. Do you perhaps have gmail or something like that so I can email you the clip?

I'll post some pics tomorrow... but I can't post clips. Do you perhaps have gmail or something like that so I can email you the clip?


Err.. Any sound clips?

I'll post some pics tomorrow... but I can't post clips. Do you perhaps have gmail or something like that so I can email you the clip?


I sent you a pm with my gmail address, if you just send me the clip ill host it for everyones listening pleasure.

I sent you a pm with my gmail address, if you just send me the clip ill host it for everyones listening pleasure.

That's great, I'll record the video today in the afternoon and I'll send you the video to your gmail by tonight :)

That's great, I'll record the video today in the afternoon and I'll send you the video to your gmail by tonight :)

thanks ill host it asap then.

still waiting on the clip, please send it so I can buy my exhaust!! lol thanks

still waiting on the clip, please send it so I can buy my exhaust!! lol thanks

Sorry I came back a little to late on Friday so it was too dark already. I promise I will record the clip Saturday morning and send to you ASAP. Trust me, you will love the exhaust.

Here are more pics of the DC Sports exhaust... dunno if you can tell that its not 100% straight from the pics though.

http://shutupndrive.com/album/albums/userpics/10002/normal_DSC01825.JPG

http://shutupndrive.com/album/albums/userpics/10002/normal_DSC01827.JPG

http://shutupndrive.com/album/albums/userpics/10002/normal_DSC01828.JPG

http://shutupndrive.com/album/albums/userpics/10002/normal_DSC01829.JPG

http://shutupndrive.com/album/albums/userpics/10002/normal_DSC01830.JPG

http://shutupndrive.com/album/albums/userpics/10002/normal_DSC01831.JPG

Beautiful isn't it?

clips!!! thanks thsiao

Clip 1 Idle
http://66.34.212.48/wrx/dcsportsidle.mpg

Clip 2 Rev, Drive Away, Drive By and Return
http://66.34.212.48/wrx/dcsportsrevdrive.mpg

Nice vids of the exhaust. Thanks for doing that as I was lagging.
Oh yeah, mine will sound different as well, due to my Headers.

-Kevin

ill host any vids or clips of exhaust if anyone wants. I would like to hear the dc sports with dp and uppipe also if someone has that combo.

I just ordered this today, the shop should have it this friday they had to order it from dc sports. How much did you pay for yours?

I just ordered this today, the shop should have it this friday they had to order it from dc sports. How much did you pay for yours?

I paid $530 for the DC Sports exhaust and $50 for installation... grand total of $580 for a great exhaust. How much did you pay?

I paid $530 for the DC Sports exhaust and $50 for installation... grand total of $580 for a great exhaust. How much did you pay?


I paid too much then $613 and self install. where did you get it at?

I paid too much then $613 and self install. where did you get it at?

I got it at Promax Motorsports on Garfield and Mission (LA County, Alhambra city I believe)... they always have good deals and cheap installation.

I got it at Promax Motorsports on Garfield and Mission (LA County, Alhambra city I believe)... they always have good deals and cheap installation.


do they have a website with that price? The local shop will match the price but I need a site with it listed.

do they have a website with that price? The local shop will match the price but I need a site with it listed.

Sorry they don't have a website... they are just a small shop. Where you live?

seattle

Mine is a bit louder to, I have the DC headers as well.

Hey, this is a great thread. I believe I have found my first mod for my STi.
Tons of info and all questions answered.
Thanks to all who added to this thread.

will this exhaust clear the optional rear diff. protector thanks

I believe so. Its perfect fitting... just pure bolt-on.

fits perfect! just got mine today, everything seems to line up good and all. well except the b&b downpipe I bought but thats another story.

fits perfect! just got mine today, everything seems to line up good and all. well except the b&b downpipe I bought but thats another story.

Just curious... how do you like the sound?

Just curious... how do you like the sound?

tad bit louder than I was hoping for but im switching to a catted dp due to no gf approval on the smell and maybe the sound will get a little better. I also ordered a silencer to see what that does it to. its not unbearable loud im just trying to make it a little more gf friendly, I can always pop the silencer out for track use.

This is the second time I have heard about the smell... Whats causing is? I can understand that an anti-rust coating may have been applied and is burning off of a new exhaust system, but this should only last a few days of good driving (maybe a week or two). What have you guys experienced? I just picked up the new DC exhaust in Corona a few days ago, installing it next Saturday. Any instal hints or tips? Sounds like most of the installs have gone well.
Thanks for the help.

my smell is from no cat, the dc sports exhaust smell is going away slowly, but ive only driven the car 2 times for more than 5 minutes so im not suprised that not everything has burnt off yet.

This is the second time I have heard about the smell... Whats causing is? I can understand that an anti-rust coating may have been applied and is burning off of a new exhaust system, but this should only last a few days of good driving (maybe a week or two). What have you guys experienced? I just picked up the new DC exhaust in Corona a few days ago, installing it next Saturday. Any instal hints or tips? Sounds like most of the installs have gone well.
Thanks for the help.

I would say that the smell from the exhaust lasts probably 1 week... and driven everyday.

Hey all -

DC Sports Cat-back exhaust and the AEM Cold Air Intake is installed on my 05 WRX STI! Install went perfectly, I had the oportunity to install the exhaust and Intake at the AEM race shop and had an excelent time, actually meeting the owner of DC Sports and AEM and having lunch with them. I have to say, I am completly impressed with their operation. They all have a drive for the highest quality product possible and they do their job well!

Like I said, the install was perfect. If it wasn't for all the Shop BS-ing, the complete install wouldn't have taken more than 2 to 3 hours for both the intake and exhaust - it was the definition of bolt on, just follow the directions provided and everything will go smoothly.

Once installed, I immediatly noticed a 15 to 25 HP gain, I am now looking at a 0-60 time of 4.2 or 4.3. I acutally liked the smell but it did go away after a solid 2 days of driving (just an anti rust coat on the exhaust).

Next step is the DC Sports Header and Downpipe. After talking to the engineer at AEM, the complete Set (Intake, Downpipe, header and exhaust) will give me just under 50 HP, bringing my wheel HP to just over 300 and flywheel HP to almost 350. I am not suprised at their dyno proven claims, after the removal of the stock intake and stock exhaust, I found more air flow restrictions than I could count! Subaru has eaten their HP up by limiting sound by the use of restrictive resonator boxes and orfaces. I would have thought that they would have gone with a higher performance air flow system... oh well, it gives us something to do with our time and $$$.

The sound is excelent, a deep rumble at idle and keeps the loud growl during acceleration. (I had a stock Nisan Z pull up next to me yesterday, reving his engine)... lets just day he didn't even look back at me after my response.

Question for all of you: I have heard that installing the header and downpipe will require some tuning of the car. Is this true? I would hate to run to lean on my fuel mix (due to increased air flow) and burn up my heads? Whats your thoughts???

All in all - excelent experience, I am in no way affiliated with AEM or DC Sports but can't say enough good stuff about them! I was able to get into their race shop because I wen't to school with their race engineer... I have to say, it added something when I was working on my car next to the 1600 HP, Honda, AEM, 6.6 sec 1/4 mile drag car... What a monster.

Thanks AEM/DC Sports.

Excellent thread! I too found my first mod for my sti...thanx to everyone's contributions. AND I live about a half an hour from Promax Motorsports...it's just meant to be :)

Is this normal? The piping joints (dunno what the technical name is) are rusting! Here are some pics. I'ved had the exhaust for about 3-4 months and I live in California. The rusting makes the exhaust piping cheap looking... although everything else is stainless steel. How is this rusting going to affect the exhaust on the long run? Any solutions to this problem? Would it help to clean it? HELP!

http://shutupndrive.com/album/albums/userpics/10002/normal_red2.JPG

http://shutupndrive.com/album/albums/userpics/10002/normal_red1.JPG

Should I complain to the exhaust manufacturer?

Is this normal? The piping joints (dunno what the technical name is) are rusting! Here are some pics. I'ved had the exhaust for about 3-4 months and I live in California. The rusting makes the exhaust piping cheap looking... although everything else is stainless steel. How is this rusting going to affect the exhaust on the long run? Any solutions to this problem? Would it help to clean it? HELP!

http://shutupndrive.com/album/albums/userpics/10002/normal_red2.JPG

http://shutupndrive.com/album/albums/userpics/10002/normal_red1.JPG

Should I complain to the exhaust manufacturer?

I'd definitely call them and follow it up with an email with pictures. The system is supposed to be 100% SS. Now, what it could be is that the flanges were cut with a grinder or some other tooling that uses a ferous metal in its composition, and some of that metal transfered when the flanges were cut. Stainless is a ***** to machine and generates some pretty decent temps when cut or ground, so metal transfer isn't out of the realm of reason. Regardless of that theory, I would still call DC. They have a warranty and from what I've heard stand behind their product.

As far as the rust spreading, kida/sorta. The rusted material can leave a residue on the adjacent stainless, but it isn't actualy oxidizing the stainless, its just basically a film of debris over the stainless.

Good luck. It's between this or the Cobb for my 05 wagon.

Chris

thsiao,

We noticed your post and want to respond. The reason you encountered rust on your exhaust flanges is because we use mild steel flanges and 100% stainless-steel piping with our exhaust systems, and it is likely that they were not treated, per our instructions, prior to installation. We do address the treatment of the flanges to prevent rust in our installation instructions.

If you follow these instructions, it will help prevent and/or get rid of rust and ensure the life span of your exhaust system.

Below is the full maintenance procedure that is included with our instructions:

=================================

**NOTE: The DC Sports Cat-back Exhaust System is manufactured from T304 Stainless Steel tubing with Mild Steel Flanges. Due to the characteristics of mild steel,* regular care/maintenance must be performed to protect against the exhaust system flanges from the elements. Failure to follow these maintenance guidelines will lead to corrosion of the flanges.

PRE-CARE MAINTENANCE
- Coat all exhaust system flanges with a light oil solution using a clean cloth (Suggestion: WD-40). DO NOT APPLY OIL TO EXHAUST TUBES!

- To prevent permanent staining of your new DC Sports Cat-back Exhaust System, wipe the exhaust tubes clean with a solution of mild detergent and water (Suggestion: Windex). Any contaminants left on the exhaust tubes such as grease, oil, and/or fingerprints will result in PERMANENT staining.
DO NOT WIPE THE LIGHT OIL SOLUTION APPLIED TO THE FLANGES. THIS OIL SOLUTION WILL PROTECT THE EXHAUST SYSTEM FLANGES FROM THE ELEMENTS UNTIL THE NEXT MAINTENANCE CYCLE.

**NOTE: During initial engine start up, you may experience smoke exiting from the muffler. Do not be alarmed. This is the bend lube from our mandrel bender settling.


POST-INSTALLATION/CARE MAINTENANCE: Your DC Sports Cat-back Exhaust System must be regularly maintained to ensure proper performance and to maintain its finish.*

- To prevent and/or remove rust from the mild steel flanges, buff the flanges regularly with Scotch Brite.
- Regularly coat all exhaust system flanges with a light oil solution using a clean cloth (Suggestion: WD-40). DO NOT APPLY TO EXHAUST TUBES!
- To restore the polished finish of stainless-steel exhaust tubes, use metal polish (Suggestions: Flitz or Mother’s Stainless Steel Polish).
- Using a solution of mild detergent and water, wipe the exhaust tubes free of all grease, oil, and/or fingerprints (Suggestion: Windex).
DO NOT WIPE THE LIGHT OIL SOLUTION APPLIED TO THE FLANGES. THIS OIL SOLUTION WILL PROTECT THE EXHAUST SYSTEM FLANGES FROM THE ELEMENTS UNTIL THE NEXT MAINTENANCE CYCLE.

* Regular maintenance depends on the weather conditions in your region. Moist or humid climates may require additional maintenance than regions that are arid. If there are any signs of rust and/or corrosion on any of the flanges, follow the instructed guidelines as soon as possible to prevent further weathering and to preserve the flange material.

=============================

We are sorry that you were unaware of this procedure prior to installation, however it appears that the rust you are encountering is treatable. Please follow these guidelines as they will protect your flanges from rust and ensure the life of your DC Sports exhaust system. If you have any further questions, please call us at (310) 484-2322.

Can I use a wire brush to brush off the rusting and then apply the WD-40? Can I get WD-40 at a local Auto Zone? How often should I do this if I live in California?

Could I also use high temp paint instead of the WD-40?

- Yes, you can use a wire brush..
- You can buy WD40 almost anywhere... AutoZone, Wal-Mart, Target, Pep Boys, etc. etc.
- Check on the flanges on a regular and just make sure they are not exposed directly to water, snow, fog, rain etc.. cause if they are, they will rust.
- High temperature paint instead of WD-40 will work fine also.

If you have anymore questions, let me know!

Wow. I am looking for the instructions that came with the exhaust I have installed. To me, spraying DW40 on exhaust pipes will do nothing, as it will instantly burn off once exhaust gets hot enough. Especially on the downpipe to exhaust flange.

Hey Alex,

The WD in WD40 stands for Water Displacement.. From the WD40 site it has these basic functions listed:

==============
DISPLACES MOISTURE: Because WD-40 displaces moisture, it quickly dries out electrical systems to eliminate moisture-induced short circuits.
PENETRATES: WD-40 loosens rust-to-metal bonds and frees stuck, frozen or rusted metal parts.
LUBRICATES: WD-40's lubricating ingredients are widely dispersed and hold firmly to all moving parts.
PROTECTS: WD-40 protects metal surfaces with corrosion-resistant ingredients to shield against moisture and other corrosive elements.
==============

yes, it will eventually burn off.. but even when you think it has burned off instantly because it is dry, it isn't necessarily gone. it does penetrate into the mild steel and will still protect against rust. i'm not saying it'll last forever, but it will help prevent rust if maintained properly and treated on a regular basis. i'd say that every time you do a routine check on your car (ie. water, oil, brakes, etc.), add rust prevention to it.. won't take but a few minutes.

Hey Alex,

The WD in WD40 stands for Water Displacement.. From the WD40 site it has these basic functions listed:

==============
DISPLACES MOISTURE: Because WD-40 displaces moisture, it quickly dries out electrical systems to eliminate moisture-induced short circuits.
PENETRATES: WD-40 loosens rust-to-metal bonds and frees stuck, frozen or rusted metal parts.
LUBRICATES: WD-40's lubricating ingredients are widely dispersed and hold firmly to all moving parts.
PROTECTS: WD-40 protects metal surfaces with corrosion-resistant ingredients to shield against moisture and other corrosive elements.
==============

yes, it will eventually burn off.. but even when you think it has burned off instantly because it is dry, it isn't necessarily gone. it does penetrate into the mild steel and will still protect against rust. i'm not saying it'll last forever, but it will help prevent rust if maintained properly and treated on a regular basis. i'd say that every time you do a routine check on your car (ie. water, oil, brakes, etc.), add rust prevention to it.. won't take but a few minutes.

Wouldn't high temp paint work better than the WD-40 then?

high temp paint would work just as good. anything to protect the mild steel against rust.

Thank you "AEM" for answering so promptly. However, I do have a couple more questions concerning the DC Sports exhaust that's on my STi. I just noticed the following 2 things this past week.

1) The part where the exhaust tip connects to the canister (where its solded) has weird colors... mostly orange/red (on the driver's side) and blueish/green (on the passenger's side). Here's 2 pics of that problem from both sides of the canister. I honestly don't recall how it looked like when it was new so I just want to make sure whether or not this color is normal or not and what is happening.

http://shutupndrive.com/album/albums/userpics/10002/normal_DSC00451.JPG
http://shutupndrive.com/album/albums/userpics/10002/normal_DSC00450.JPG


2) I believe the canister and the tip have the same stainless steel finish right? I just cleaned my exhaust today and noticed that the tip and the canister looks different... the canister was shinny and nice looking, while the tip looked dull, bronze looking, and simply not shinny like the canister. The difference is really obvious, and no matter how hard I tried cleaning the tip it was useless (I only used a wet cloth to clean). When I took the pics and cleaned the exhaust, the exhaust was not hot at all... the car has been sitting there the entire night. I recall that both the canister and the tip was the same finish. Is there something wrong with my exhaust? Same problem with the piping... becoming dull and bronze color, rather than stainless steel color. What can I use to clean it so that the tip will be shinny like the canister? Here are 2 pics for you to compare what I am talking about.

http://shutupndrive.com/album/albums/userpics/10002/normal_DSC00455.JPG
http://shutupndrive.com/album/albums/userpics/10002/normal_DSC00452.JPG


... And compare those 2 pics to this photos which was taken when the exhaust was brand new.
http://shutupndrive.com/album/albums/userpics/10002/normal_DSC01831.JPG


Any feedback would be deeply appreciated. Sorry, I am just super anal about my car and how everything looks.

BTW, I tried using Mother's "Mag and Alum" polish ("Great for ALL Metals") and it doesn't work either... its a bit shinnier but still bronze looking when compared to the canister. What can I do to restore my tip and piping?!?!?!?!?!?! Any specific brand and model that would REALLY work so I don't need to keep spending my money on unnecessary stuff? Thanks.

The color you see is caused from heat. It can not be polished out to my knowledge.
My flanges have done the same as yours (rusting). I plan on High temp painting all my flanges to stop the rust and reduce maint.

-Kevin

The color you see is caused from heat. It can not be polished out to my knowledge.
My flanges have done the same as yours (rusting). I plan on High temp painting all my flanges to stop the rust and reduce maint.

-Kevin

Are you refering to the color in the solded part where the tip meets the canister or the dull bronzeish color of the tip itself?

Some info for thsiao and others....

I took my exhaust off today to paint the flanges with high temp ceramic paint.
To my dissapointment, I found further problems with my exhaust. A common problem with stainless exhaust systems is there durability. Many will crack over time on the flange and hanger welds. Stainless steel does not handle heat expansion and contraction very well.

My exhaust had a few pin hole cracks on the flanges, and one on the muffler cannister seam next to a hanger weld. I can understand the flanges made of mild steel rusting, but the stainless piping is rusting as well. I tried to clean the pipes as suggested, but the rust staining is there to stay. The polished (chromed?) muffler also has rust spots that will not come off as well.

I take into consideration, that the 4+ months the exhaust has been on, the car has been through some serious tracking. But really, I had a TurboXS system on my wagon for over a year without any rust on any part of the exhaust. On the other hand, my STi has spent most of it's time in the last four months in a shop or trailer. It has never seen snow, or excessive moisture conditions.

Here are a few pics of the flanges, piping, muffler and spot welds for a temporary fix.
I am considering having the most of the exhaust ceramic coated inside and out down the line.

-Kevin- "Not Happy after 4 months"

Are you refering to the color in the solded part where the tip meets the canister or the dull bronzeish color of the tip itself?

As far as the bronze tint goes on the tip, that is due to heat. I personally like it. It shows that it gets used. The dullness I can see in your pics is not regular. I can only assume that it was scratched/buffed is some way. My tip is bronze, rusting a bit, but it is still shiny for the most part. You might want to start checking around all of the flanges for black marks. They are indications of cracks.

Good luck,
Kevin

That is why I was surprised to know that the pipes and SS and the flanges are MS. Those two do not weld that good. Not sure what the reasoning behind doing so is, but I hope it gets resolved.

I hope AEM can explain to us why this product lacks the quality we were all EXPECTING from DC Sports... if I had known all these problems would had emerged from bad quality, I would had definitely gone with another brand. This is really upsetting. I want a refund men... this exhaust is bad quality and after ONLY 4 months of use its totally ridiculous.

The dullness I can see in your pics is not regular. I can only assume that it was scratched/buffed is some way. My tip is bronze, rusting a bit, but it is still shiny for the most part. You might want to start checking around all of the flanges for black marks. They are indications of cracks.


I don't think the dullness is because it was scratched because I am very careful with my exhaust and I have never scratched it. There are tons of black marks on the flanges... does that mean its cracked.

I don't think the dullness is because it was scratched because I am very careful with my exhaust and I have never scratched it. There are tons of black marks on the flanges... does that mean its cracked.

Wipe the black spots with your finger, if it wipes off on your finger, there is probably a crack or pinhole. It may be leaking gaskets as well. Two bolt gaskets blow out easily. Mine are toast already, and leaking. The gaskets they come with suck.

Wipe the black spots with your finger, if it wipes off on your finger, there is probably a crack or pinhole. It may be leaking gaskets as well. Two bolt gaskets blow out easily. Mine are toast already, and leaking. The gaskets they come with suck.

So what do we do if its leaking? Sh!t this whole ordeal totally sucks. AEM is private messaging me about our problem... he's researching, maybe he'll have some solutions for us.

wrexr, what other exhausts were you considering when you got this one? What other exhaust would you get NOW after this incident?

I want an exhaust that looks like the DC Sports one (straight design, tip exactly where its suppose to be... not close to bumper so it wont burn it and sticking just enough to not discolor bumper, with no installation/fitment problems, and as loud or louder). I think we will be forced to get a new exhaust soon... ****. And I thought I had found the "perfect" exhaust...

So what do we do if its leaking? Sh!t this whole ordeal totally sucks. AEM is private messaging me about our problem... he's researching, maybe he'll have some solutions for us.

wrexr, what other exhausts were you considering when you got this one? What other exhaust would you get NOW after this incident?

I want an exhaust that looks like the DC Sports one (straight design, tip exactly where its suppose to be... not close to bumper so it wont burn it and sticking just enough to not discolor bumper, with no installation/fitment problems, and as loud or louder). I think we will be forced to get a new exhaust soon... ****. And I thought I had found the "perfect" exhaust...

AEM is private messaging you? I have not heard a thing.WTF

I got this exhaust as a special deal for the tech article. While the performance gains were on the mark, the durability is not there. I will be waiting to hear what AEM/DC Sports has to say about all of this.

Let me know if you hear anything,
Kevin

AEM is private messaging you? I have not heard a thing.WTF

I got this exhaust as a special deal for the tech article. While the performance gains were on the mark, the durability is not there. I will be waiting to hear what AEM/DC Sports has to say about all of this.

Let me know if you hear anything,
Kevin

Don't worry, I'll be sure to let everyone know what is up with this product. Nobody expects their $600 exhaust system to be so problematic after ONLY 4 months of usage... I don't even take my car to the tracks, just regular daily use. I am so upset and I am also waiting to hear what they'll say.

thsiao:

All of the discoloration symptoms are very normal. Due to the characteristics of stainless steel, discoloration occurs upon heat penetration directly to the stainless steel metal. In result of the welding process, heat is directly absorbed onto the stainless steel exhaust, creating this rainbow-like discoloration.

Furthermore, the bronze b-pipe and tip are also a normal symptom. When stainless steel is heated, the finish will discolor to a bronze color. Also, the reason why the muffler does not discolor like the b-pipe and tip is because the hot exhaust gas is absorbed by the muffler packing, not allowing the muffler to get hot enough to discolor.

If you really wanted to, it can be buffed out using any high-quality metal polishing compound.
I had one of the DC Sports Engineers take an exhaust with a bronzed tip and try to buff it out.
Using Mothers polish, he was able to successfully do so with an extreme amount of pressure.
He said you cannot simply rub the polish on. A great amount of pressure is needed. He suggests using a high speed buffer.
Please remember, after doing this, the bronze color will return.

Would you be willing to bring your car down to the DC Sports facility so we can see the rusting problem first hand? We’d like to check out your system and help treat the rust issue before it gets any worse.


wrexr:
In your case, since you were the recipient of the exhaust for the install article, email me directly as we would need to get that exhaust back to see the cause of any cracks and pinholes. This should not be happening. If there is anyone else with this problem, please call our warranty department @ (310) 484-2322 immediately, so we can inspect the exhaust and remedy the situation.

Would you be willing to bring your car down to the DC Sports facility so we can see the rusting problem first hand? We’d like to check out your system and help treat the rust issue before it gets any worse.


Where is the DC Sports facility located? What is your name? I'll try to remove the rust on the flanges and spray the flanges with WD-40 and also try to polish the tip and the piping to see if I can restore the original color. I bought a Mother's metal polish. I'll also inspect my exhaust to see if its as bad as wrexr's... although I suspect that the rusting is only on the flanges as of right now (knock on wood). I'll update tomorrow so please check tomorrow afternoon for the update. Thanks AEM for the help.

The DC Sports facility is located in Corona, probably about 45 minutes from where you live. My name is Dennis. Let me know if you are interested in going to DC Sports and I can schedule a day so we can check it out.

The DC Sports facility is located in Corona, probably about 45 minutes from where you live. My name is Dennis. Let me know if you are interested in going to DC Sports and I can schedule a day so we can check it out.

I am interested in going to DC Sports. However, I am only free on Fridays during weekdays... so next Friday would be a good day. What is the exact address?


On the bronze and dullness on my tip:
I managed to bring some of the shiness back to the tip with Mother's metal polish. It's still a little bronze and it still does not look like the canister but at least its a little shinny now.

On the flanges being rusted:
I used a wire brush to brush away the rust and then applied WD-40 like instructed in the instructions. Visible rust was only seen on the flanges near the muffler and the center one... the one close to the engine seems fine so far so I didn't bother applying WD-40 on that one since its kinda hard using only a hydraulic jack in my garage. I later wiped the tubes near the flanges with a mixture of water and windex to remove any WD-40 mistakenly sprayed on the tubes as instructed. My exhaust system does not look nearly as bad as wrexr's since I only noticed rust on the flanges and nowhere else. I didn't see any cracks or pinholes to my knowledge (but then again I am not tech experienced). Here are some pics of before applying WD-40 and after applying WD-40.

BEFORE applying WD-40 and AFTER I had wire brushed the flanges:
http://shutupndrive.com/album/albums/userpics/10002/normal_DSC00459.JPG

http://shutupndrive.com/album/albums/userpics/10002/normal_DSC00461.JPG

http://shutupndrive.com/album/albums/userpics/10002/normal_DSC00457.JPG



AFTER applying WD-40 (and after cleaning tubes) and AFTER I had wire brushed the flanges:
http://shutupndrive.com/album/albums/userpics/10002/normal_DSC00463.JPG

http://shutupndrive.com/album/albums/userpics/10002/normal_DSC00464.JPG

http://shutupndrive.com/album/albums/userpics/10002/normal_DSC00465.JPG


How does that look?

wow...thanks for the updates Kevin.

I won't be considering this exhaust until they make some changes. Their quality is usually top notch.

I'll go back to looking at perrin and borla.

A little off topic here... but AEM, do you know how loud the DC Sports exhaust is (in db) at idle and at 3000rpm? Thanks!

AEM, I was just wondering... if we had left the rusting on the flanges (say we never noticed), how long before the exhaust starts to leak or before the flanges are severly and irreversibly damaged?

Anyone know if this exhaust is smog legal in CA?

Anyone know if this exhaust is smog legal in CA?

A cat back exhaust is legal in California. A Turbo back is not. California Exhaust decibel limit is 95db.

-Kevin

i have a question. i posted this on the ej20t forum but nobody seems to give a rats ass about any questions not related to bov's, cai's, or vf34's.

anyway, i too purchased the dc exhaust and now i too have rusting on my flanges. i am going to do the wirbrush/hi-temp paint thing to try and remedy the problem.

however, if i take my exhaust apart, i want to know if i can use the same gaskets or should i look into replacing on the re-installation?

I would suggest replacing the gasket, the DC sports gaskets tend to tear apart after one use and only a few thousand miles, they do seal well but I would get a few gaskets like this...http://www.subydude.com/parts/details.php?605

I have one between my downpipe and catback, they are very good gaskets and as far as I can tell you can reuse them easier than the dc sports gaskets.

I would suggest replacing the gasket, the DC sports gaskets tend to tear apart after one use and only a few thousand miles, they do seal well but I would get a few gaskets like this...http://www.subydude.com/parts/details.php?605

I have one between my downpipe and catback, they are very good gaskets and as far as I can tell you can reuse them easier than the dc sports gaskets.

Does that mean I have to replace my gaskets even if I DONT take off the exhaust? WTF? Doesn't make any sense...

i dont understand why you should have to maintain the exhaust itself, no other exhaust systems require spraying wd40 on the flanges to maintain them and to keep them from rusting.
I have a blitz nurspec with over 9,000mi with no signs of rust or any corosion,it seems like quality problem because to many people are having problems with this exhaust.

well, i tackled the rust job this weekend and i am pretty pleased, but only time will tell if it was effective. i took apart the complete 3 pc. exaust and 2 of the 3 gaskets ripped upon separating the flages. the one closest to the downpipe stayed intact. i wire-brushed and hand sanded the flages till both my hands were dead tired and there was still a bit of discoloration but i figured it was as good as it was going to get. i then covered the pipes and sprayed the flanges with 2 coats of hi-temp primer. would have done a third coat, but it was getting dark.

since the two gaskets ripped i went down to autozone and picked up a made-to-cut gasket sheet. looked and felt exactly the same as the ones provided by dc 'cept these were beige in color. used the old gaskets as a stencil, then traced and cut out 2 new gaskets. (btw, the sheet is huge as it is made for headers and i think i can cut out at least 12 more gaskets from it! lol) anyway they fit perfect and made a good seal. i sure hope it lasts. i really like the exaust, but i sure didn't bargain for all the maintenance!

This entire maintenance thing is just ridiculous... the WD-40 doesn't really work on the flanges. Now I'm even scared of driving my car out when its raining simply because I don't wanna go through all that hassle of wire brushing the damn flanges every time it rusts! Its just tooooo much freakin work that NO OTHER aftermarket exhaust seems to have... definitely a quality problem and apparently a cost cutting decision that was one hell of a bad call.

will this exhaust bolt up to my 05 2.5RS? if not what modifications are neccessary?

I was really considering and excited about the DC Sports exhaust until I read this whole thread I even went and got part ##'s and was getting prices from my local dealer. I am now thinking if they go with stainless flanges I still may consider but otherwise I will probably go with the Borla.

i just bought a 2004 wrx and i want to be as much as a sleeper as possible but i want my exhaust to be quiet(er) so it adds to my sleeper quality, during acceleration does the exhaust become really loud where it doesn't sound good anymore or takes away from the ride, also i want to install my own exhaust and i have everything needed to install the exhaust but is a lift nexessary or can u just raise the car with jacks a couple of feet or will that not be enough

i just bought a 2004 wrx and i want to be as much as a sleeper as possible but i want my exhaust to be quiet(er) so it adds to my sleeper quality, during acceleration does the exhaust become really loud where it doesn't sound good anymore or takes away from the ride, also i want to install my own exhaust and i have everything needed to install the exhaust but is a lift nexessary or can u just raise the car with jacks a couple of feet or will that not be enough

a lift is pretty crucial when working on an exhaust system.

-Noah

clips!!! thanks thsiao

Clip 1 Idle
http://66.34.212.48/wrx/dcsportsidle.mpg

Clip 2 Rev, Drive Away, Drive By and Return
http://66.34.212.48/wrx/dcsportsrevdrive.mpg
is this just the catback or do you have a downpipe as well?

is this just the catback or do you have a downpipe as well?

Just cat-back.

I'm getting a new 2006 WRX within a few weeks and have 2 questions.

1.) Has DC sports fixed the issue with the mild steel couplings on the exhaust system rusting?

2.) The AEM/DC sports site only lists the system as working up through the 2004 model year. Will it fit without any mods on the 2006?

email them and ask. if your in so cal who knows maybe you can test fit for them.