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First things first anyone who undertakes the mod does so at their own risk i will not be held responsible for any damage incurred during this mod. Having said that it seems like a safe mod to me.

Tools needed
-13mm socket and extension
-1/2” spline drivers
-angle grinder with a 1mm cutting disk
-mig welder
-gray high temp paint

1: get the car up on a lift or on axle stands. take the cassis brace in the middle of the exhaust by undoing the 4 spline bolts, also remove the exhaust brace using a 13mm socket.



2: next undo the 8 13mm nuts and bolts holding the 4 exhaust mounts and rubber to the underside of the car, before taking the bolts out rest the back boxes and the resonators on something i.e. a stack of wood so they stay in place.



3: now undo the exhaust clamp behind the cats or bypass pipes and slide the whole exhaust towards the back of the car until it comes free from the cat pipes. once free you can remove the chocks from under the exhaust and slide the whole system forwards and it should drop out.



4: with the exhaust off you can now cut the back boxes open and remove the glass fibre with a large screw driver. take your time and make sure not to hit the cross baffle in the back box this is under the first ridge from the front of the box so cut just behind that. One small point to note is that some people have opted to wrap the internal perforated pipe i chose not to.




5: blow the box out with an air line then clean all the burs of using a flap disk. now tack the panel you removed back into place then weld back up be careful not to use too many amps as your filling an air space. after its all welded up put a coat of HTP on the welds.



6: refit is the reverse of removal

the noise in my opinion is much improved above 3000 Rpm and close to the redline you get a much more turbo v10 sound. there is a small amount of done but nothing to bad with the radio on its barely noticeable.

Great write up mate will be using this for when I do mine .

Thanks for the write up. Do you think wrapping the pipe will increase the noise level?

I think it would make the exhaust sound more straight pipes you would struggle to wrap the really short price between the internal baffle and the exhaust main pipe

This is an interesting mod, do you have any pictures of the glass fibre that you removed, or any pictures of it installed and then removed?

I did this mod some time ago. I would say not much of a difference at all. Perhaps a bit meatier sound up in the revs......

I just did this mod yesterday. After removing the fibre glass packing material I wrapped the pipe with aluminium foil and then exhaust wrap.
The sound is a lot deeper at idle and through the rev range. Its louder at cold start which is to be expected but not as bad as my old rs4 without cats and free flow exhaust. I haven't noticed any drone at cruise which is good.