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Having a dual tip RE exhuast on my ti is nice, except for the fact that the rear diffuser needed the exhaust cut out to be enlarged. The stock cut out has nicely finished end caps, whereas the "custom" cut out removes these and leaves an empty space (see pic). It's not the ideal factory look that I'm always striving for.
I bought a 323ti rear diffuser from Steven, but that dual tip cut out wasn't wide enough. It would still need to be enlarged, but would then still be without the end caps. Then I came upon a method for repairing plastic bumpers. A body shop near me that I've used before knew how to do plastic welding, so I took a dremel to Stephen's pristine 323ti diffuser and I stratigically made a few cuts to widen the cut out while preserving the end caps. I then had another junked ti diffuser that I used to cut out filler pieces to fill in the gaps after widening the 323ti cut out. About 5 pieces in all were used to reconstruct a new factory appearing diffuser. Take a look at the results. It now looks factory!
Before: __________________
'95 330ti CS w/sr delete, S50USB30, cams, 24# inj, Conforti SW, Euro HFM, Samco Silicone Intake Boot, BBTB, Euro Oil Cooler, JTD CAI Duct, RE DMS exhaust, RE Tranny mounts, CF Valve Cover, LTW flywheel/Kevlar sprung hub clutch, RE SSK, 3.46 Finned LSD (M6) , M3 tranny, Brembos, RE Wheel Studs, SS brake/clutch lines, CF interior, Rear Headrest retrofit, Tilt Steering retrofit, 13.5 lb DynaBatt in rear, LED interior/footwell lights, ZKW HID, Headlight Aim Control, Rear fog light w/cluster indicator, CF 3 Aux gauge pod, BMW Traffic Pro/Alpine MP3-CD Changer, Staggered LTW wheels, '95 M3 steering rack, VIS CF Hood, M3 LTW Strut Bar, TCK SA coilovers, Red LTW Motorsport Seatbelts, OEM Fire Extinguisher, Z8 Starter button, Auto dim rear view mirror w/ Homelink/Compass, PDC, Rear Sun Shade, Euro Gauge Cluster w/oil temp/shift light , Headlight Washers, "Motorsport" Door Handles, CF Grills, French ZKW Fogs, Euro dash bins, Power Lumbar Support is next, Coming e39 M5 interior light, Bimmer Magazine 8/2007 |  |  | | 05-16-2006, 04:05 AM | #2 | | Senior Member Join Date: Nov 2003 Location: Walnut Creek, CA Posts: 642 |
After: The factory look __________________
'95 330ti CS w/sr delete, S50USB30, cams, 24# inj, Conforti SW, Euro HFM, Samco Silicone Intake Boot, BBTB, Euro Oil Cooler, JTD CAI Duct, RE DMS exhaust, RE Tranny mounts, CF Valve Cover, LTW flywheel/Kevlar sprung hub clutch, RE SSK, 3.46 Finned LSD (M6) , M3 tranny, Brembos, RE Wheel Studs, SS brake/clutch lines, CF interior, Rear Headrest retrofit, Tilt Steering retrofit, 13.5 lb DynaBatt in rear, LED interior/footwell lights, ZKW HID, Headlight Aim Control, Rear fog light w/cluster indicator, CF 3 Aux gauge pod, BMW Traffic Pro/Alpine MP3-CD Changer, Staggered LTW wheels, '95 M3 steering rack, VIS CF Hood, M3 LTW Strut Bar, TCK SA coilovers, Red LTW Motorsport Seatbelts, OEM Fire Extinguisher, Z8 Starter button, Auto dim rear view mirror w/ Homelink/Compass, PDC, Rear Sun Shade, Euro Gauge Cluster w/oil temp/shift light , Headlight Washers, "Motorsport" Door Handles, CF Grills, French ZKW Fogs, Euro dash bins, Power Lumbar Support is next, Coming e39 M5 interior light, Bimmer Magazine 8/2007 | | | | | 05-16-2006, 04:24 AM | #3 | | Senior Member Join Date: Aug 2005 Location: Melbourne, Fl/Athens, AL Posts: 393 |
Looks great. I need to look into something like this to fill in some spots on my splitter...
BTW, dual tips=sexy. Or rather, your entire car is sexy. __________________ -Kenny
 | | | | | 05-16-2006, 04:30 AM | #4 | | aka Stabby Join Date: Nov 2004 Location: Mead, CO Posts: 5,336 |
uh-oh, more sexy car talk. looks good clex! they did nice work, looks perfect in the pics. __________________ 1996 318ti, California package, 267k miles
current mods: bilstein sports, bavauto springs, e30 m3 LCABs, solid metal ball joints, bavauto RSMs w/reinforcements, e30 3.73 LSD & halfshafts, supersprint cat-back exhaust, turner rear sway bar reinforcements, IE poly subframe & RTABs + camber/toe kits, powdercoated e36 32x front calipers, sport mirrors, H&R 28mmF/19mmR sway bars, x-brace, auto solutions SSK w/poly bushing upgrade, BMW CD43 head unit, DICE HD Radio w/iPod integration and "stealth" HD antenna, staggered style 68s, orange electronic TPMS, leather arm rest, JT Designs metal undertray
acquired and awaiting install: heated seat kit, cali top switch relo, lumbar support kit, park distance control kit, heated washer nozzle kit, m-coupe rear subframe, trailing arms, differential, and halfshafts, m-coupe front/rear brakes with master cylinder, under hood light kit, mud flaps, rear sun blind, auto-dimming rear view mirror, tilt steering wheel retrofit, apexcone 5000K HIDs with 55W ballasts
2002 X5 4.4 Sport Package, 53.5k miles
Current Mods: e46 m3 steering wheel | | | | | 05-16-2006, 06:26 AM | #5 | | Senior Member Join Date: May 2005 Location: CG68 Posts: 280 |
That turned out BEAUTIFULLY. | | | | | 05-16-2006, 07:30 AM | #6 | | Senior Member Join Date: Feb 2005 Location: Marin County & Santa Cruz Posts: 116 |
hopefully it won't melt when you get on it. | | | | | 05-16-2006, 06:00 PM | #7 | | Senior Member Join Date: Nov 2003 Location: Walnut Creek, CA Posts: 642 |
Quote: | Originally Posted by SlickmisterN hopefully it won't melt when you get on it. | Thanks for the compliments. The cut out is exactly the same dimensions as the old one, which shows no signs of melting. The new diffuser has a few hundred miles on it, and also no melting. I would cry if it got melted. __________________
'95 330ti CS w/sr delete, S50USB30, cams, 24# inj, Conforti SW, Euro HFM, Samco Silicone Intake Boot, BBTB, Euro Oil Cooler, JTD CAI Duct, RE DMS exhaust, RE Tranny mounts, CF Valve Cover, LTW flywheel/Kevlar sprung hub clutch, RE SSK, 3.46 Finned LSD (M6) , M3 tranny, Brembos, RE Wheel Studs, SS brake/clutch lines, CF interior, Rear Headrest retrofit, Tilt Steering retrofit, 13.5 lb DynaBatt in rear, LED interior/footwell lights, ZKW HID, Headlight Aim Control, Rear fog light w/cluster indicator, CF 3 Aux gauge pod, BMW Traffic Pro/Alpine MP3-CD Changer, Staggered LTW wheels, '95 M3 steering rack, VIS CF Hood, M3 LTW Strut Bar, TCK SA coilovers, Red LTW Motorsport Seatbelts, OEM Fire Extinguisher, Z8 Starter button, Auto dim rear view mirror w/ Homelink/Compass, PDC, Rear Sun Shade, Euro Gauge Cluster w/oil temp/shift light , Headlight Washers, "Motorsport" Door Handles, CF Grills, French ZKW Fogs, Euro dash bins, Power Lumbar Support is next, Coming e39 M5 interior light, Bimmer Magazine 8/2007 | | | | | 05-16-2006, 06:56 PM | #8 | | Senior Member Join Date: Aug 2004 Location: state college, pa Posts: 3,431 |
Quote: | Originally Posted by SlickmisterN hopefully it won't melt when you get on it. | It shouldn't. Plastic welding is used frequently for motorcycle fairings, where the motor/transmission/exhaust is right next to it. In the right hands, the results are amazing. I'll post pics when I can of my front cowling pre and post-fix. I got into a scuffle with a Jeep Grand Cherokee a while back, and it's impossible to tell anything ever happened. __________________
I scream, you scream, we all scream for ZOMBIES. | | | | | 05-18-2007, 08:12 AM | #9 | | Senior Member Join Date: Feb 2007 Location: DoWNeY, CALiFORNiA Posts: 141 |
Quote: Originally Posted by clex2  After: The factory look | Wow thats amazing, if i'd known that, I would of looked into doing that instead. Looks awsome. I really hated to cut my stock diffuser. Just look cheap. But maybe it can still fix it if I find another diffuser from a wrecked TI. Who knows? | | | | | 05-18-2007, 10:51 PM | #10 | | Senior Member Join Date: May 2006 Location: Memphis, Tn Posts: 1,299 |
looks real good man. I like the dual tips, i have some too. I need to get my rear end plastic done like urs too. __________________
custom dual exhaust,M3 front and rear bumper, 10.4 inch roof mount drop screen, Viper alarm system, DSII's rims, M3 Vader Seats, M3 Mirrors, Carbon Fiber CAI, Smoked Corners, Side Markers, Leatherz armrests, black grilles
225k miles and still the Ti goes on | | | | | 05-19-2007, 12:39 AM | #11 | | Senior Member Join Date: Nov 2006 Location: Stamford, CT <-> Boston, MA Posts: 1,393 |
Wow, that's all I can say. Nice job | | | | | 05-19-2007, 01:44 AM | #12 | | Senior Member Join Date: Jan 2005 Location: Fort Collins, CO Posts: 1,305 |
that looks awesome!! How much wider than the 323 diffuser cutout is it? | | | | | 05-19-2007, 06:15 AM | #13 | | Senior Member Join Date: Nov 2003 Location: Walnut Creek, CA Posts: 642 |
Quote: Originally Posted by PettitWC that looks awesome!! How much wider than the 323 diffuser cutout is it? | The RE DMS tips needed 50% more cutout width then the stock 323ti diffuser. This is one of those mods that is so subtle that almost nobody will notice because it looks abosolutely stock. That is, until you point it out to them...... __________________
'95 330ti CS w/sr delete, S50USB30, cams, 24# inj, Conforti SW, Euro HFM, Samco Silicone Intake Boot, BBTB, Euro Oil Cooler, JTD CAI Duct, RE DMS exhaust, RE Tranny mounts, CF Valve Cover, LTW flywheel/Kevlar sprung hub clutch, RE SSK, 3.46 Finned LSD (M6) , M3 tranny, Brembos, RE Wheel Studs, SS brake/clutch lines, CF interior, Rear Headrest retrofit, Tilt Steering retrofit, 13.5 lb DynaBatt in rear, LED interior/footwell lights, ZKW HID, Headlight Aim Control, Rear fog light w/cluster indicator, CF 3 Aux gauge pod, BMW Traffic Pro/Alpine MP3-CD Changer, Staggered LTW wheels, '95 M3 steering rack, VIS CF Hood, M3 LTW Strut Bar, TCK SA coilovers, Red LTW Motorsport Seatbelts, OEM Fire Extinguisher, Z8 Starter button, Auto dim rear view mirror w/ Homelink/Compass, PDC, Rear Sun Shade, Euro Gauge Cluster w/oil temp/shift light , Headlight Washers, "Motorsport" Door Handles, CF Grills, French ZKW Fogs, Euro dash bins, Power Lumbar Support is next, Coming e39 M5 interior light, Bimmer Magazine 8/2007 | | | | | 05-19-2007, 06:20 AM | #14 | | Senior Member Join Date: Jan 2005 Location: Fort Collins, CO Posts: 1,305 |
damn, that's a lot more than i thought it would be. I was thinking about a dual tip exit but I was thinking it would fit in a factory 6 cyl diffuser...this opens up a whole new realm of possibilities though | | | | | 06-07-2007, 11:43 PM | #15 | | Senior Member Join Date: Aug 2006 Location: Cashville,TN Posts: 124 |
Tin snips and a hot razor blade FTW!! __________________ 
Mmm.. | | | | | |
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