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Discussion Starter #1 (Edited)
There is a lot of information floating around the forum in regards to methods and products used to modify the exhaust on a 2003-2011 Focus with either the 2.0 or 2.3 Duratec; but I haven't seen any specific thread that tackles all of the common questions and concerns with the topics.

This thread will cover:
1. Available flex-back exhaust kits.
2. Interchangeability of kits made for certain model years and body styles.
3. How much power to expect from a flex-back exhaust system.



1. There have been countless flex-back exhaust systems made for the Duratec Focus, here's a basic list of the kits that are currently available with a run-down of their basic pros and cons.

-FSWerks Stealth: As far as exhaust kits are concerned, my opinion is that there is not a single currently available kit that is better suited for a street-used Ford Focus.
Price: $459.95
Pros: Unmatched sound by any other kit currently on the market, world-class build quality, the right materials. Perfect for the daily driver. Unbelievable value.
Cons: This is one of the most popular kits being sold for our cars, so you will wind up sounding like a lot of other Focuses. One of the quieter kits.
Links:
Sedan/coupe: http://www.fswerks.com/collections/exhaust/products/fswerks-stealth-exhaust-system-ford-focus-coupe-sedan-2008-2011
ZX3/ZX5: http://www.fswerks.com/collections/exhaust/products/fswerks-stealth-exhaust-system-ford-focus-zx3-zx5-hatchback-2000-2007
Sound Clip: http://www.youtube.com/watch?list=UUwJY2rWaz33Mk4cZ9LcJBOA&v=4LpkCpBmWAg#t=52


-FSWerks Race: Another tremendous offering from the crew at FSWerks. Be warned, the name is not to be taken lightly.
Price: $399.95
Pros: Remarkable value, top-notch quality, perfect for a track car on a budget.
Cons: Absolutely NOT for use with a header. The sound this system makes with a long-tube, catless header is horrible. Go for the Stealth if you have a header. This kit is widely considered too loud for a street car.
Links:
Sedan/Coupe: http://www.fswerks.com/collections/exhaust/products/fs022ssq
ZX3/ZX5: http://www.fswerks.com/collections/exhaust/products/fswerks-race-exhaust-system-ford-focus-zx3-zx5-hatchback-2000-2007
Sound Clip: http://www.youtube.com/watch?v=4LpkCpBmWAg&list=UUwJY2rWaz33Mk4cZ9LcJBOA


-Borla: One of countless kits offered for cars of all types by Borla, this kit is known to last in bad conditions, and provides a quiet, yet assertive note.
Price: $620.50
Pros: Quality, fitment, good materials. Borla is known to build a very nice exhaust system.
Cons: In comparison to FSWerks, the price of this kit is almost inexcusable. If you have a 2005-2011 Focus, this kit will need to be modified to clear your fuel tank.
Link: http://www.borla.com/products/focus_catback_exhaust_part__140018.html
Sound Clip: http://www.youtube.com/watch?v=BF0lZJJHfn8


-TruBendz/Magnaflow: Available with both 2.25" and 2.5" piping, this is a popular kit for enthusiasts who are on a budget. Beware, this kit is inexpensive for a reason. The piping is made of thin material and the fit can be frustrating.
Price: $345.00
Pros: Inexpensive, choice in piping size.
Cons: Some have issues with installation due to poor fitment, others do not. Thin, cheap piping. Corrosion will be an issue.
Links:
-2.25": http://www.mandrelexhaustsystems.com/servlet/the-216/05-dsh-11-FORD-FOCUS-EXHAUST/Detail
-2.5": http://www.mandrelexhaustsystems.com/servlet/the-215/05-dsh-11-FORD-FOCUS-EXHAUST/Detail
Sound Clip: http://www.youtube.com/watch?v=QMx0yc4DLvM

-Magnaflow Another high-quality kit from an exhaust giant, the Magnaflow system offers a mellow, deep tone. The pipe sizing is controversial.
Price: $586.90
Pros: Good sound, friendly to the neighbors, well-known quality.
Cons: Very expensive, piping does not allow for much room to grow, tip is a bit too "stealthy" for some.
Link: http://www.c-f-m.com/performanceparts/pc/WE-MATCH-PRICES-Magnaflow-2-25-inch-Cat-Back-Exhaust-System-for-04-06-ZX4-08-09-Focus-Coupe-79p1454.htm#.UuGTeBAo7IU
Sound Clip: http://www.youtube.com/watch?v=ESwEA8AQOHU

2. The kits I have listed above are the ones that are clearly listed to fit our cars. There are many, many other options out there if you are willing to get a bit creative. Here's a run-down of what you will have to do to make them others fit.
-SVT/Zetec Fitment: This is a bit of a tricky one. Kits made for the SVT and base MK1 Focus have a different front flange on them, so you will need to remove it and either weld on a Duratec-specific flange or use a band clamp and slip-fit connection to join it with your flex-pipe. Also a concern, later Duratec cars ('05 and up) have, in many cases, a 14-gallon fuel tank versus the SVT/MK1 12-gallon tank. So kits will clear, other will not. Changing the orientation of the muffler in these kits will normally solve the issue, though.
-Making it work with a wagon: If you're one of the guys out there cool enough to modify a wagon, you will have more difficulty with your exhaust than others. Since your car is longer than our, you will have to extend the tailpipe several inches to reach your rear bumper.


3. This is a bit of a grey area. The bottom line is this: Don't expect much. The 2.25" systems that are available offer (normally) a 4-6hp increase at the wheels on a stock car, and the 2.5" systems will offer another 2-5whp on top of that. Since we are talking about such small numbers, variables in the car's age, mileage, mechanical condition, and even ambient temperature will cause varying results.

Magnaflow 2.25"


FSWerks 2.5"


Keegan|Brock Development 2.5" (Just results, no graph)





**I will be expanding this thread over time with more info, product updates, etc. If you have something to add, please feel free to post it right in the thread!**
 

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I have a Borla on my car. I did not pay anywhere close to the $620 quoted above (and I would not pay that much for one....that's crazy!).

Price aside, it is an excellent exhaust; great fit, quality, and the sound is mellow and aggressive but not obtrusive.

While I have not had my car on a dyno, my internal dyno indicated a bit more torque after the install.
 

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Great info! I have a question on making them work for the wagon (hopefully one of the other wagon guys can chime in as well) - I'm looking this summer to get the FSWerks stealth for my wagon - would a regular exhaust shop be able to tackle welding in an extension piece between the muffler and the tip? How much longer does it need to be to fit well? I'm also assuming those numbers posted are coming from a car without an aftermarket header, correct?! I only ask because I'm looking into that as well.
 

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Potato Camera Operator
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Discussion Starter #5
Yes, all of the cars whose dyno sheets are posted have only an exhaust system installed. For clarity, my car had a Marcy intake at the time, but after discussing the matter with Ray at McNews, the filter I had on it and the general design of the product probably combined to create no actual power gains.

In regards to your extension, my last recollection tells me your tailpipe will need to be about 11" longer than that of a sedan. Any shop will be able to tackle the project with ease, though I would suggest seeking a shop that can TIG weld the extension so that it matches the craftsmanship of the original product.

Todd: where did you buy your exhaust? Shoot me a link if you could so that I can update the OP.


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Small update for the Magnaflow. Some of them like the Roush version of it is a 2nd cat back setup. Still legal in CA and other places that do visual checks. Their is no flang to line up, just cut behind the 2nd cat and slip the new pipe on. The muffler is a small 4in round and has no problem clearing any of the fuel tanks.

Another update on the Roush. Had one come in the shop with the "Roush Performance" tip. The muffler was a 6in offset muffler and the last hanger was slightly different to mine. Caught me way off guard when I saw it, sound was still the same just not the same amount of noise. Was still a 2nd cat back system.
 

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I have the FSWERKS Stealth on my car, and I am delighted with it. It has a low rumbley tone up to about 3000rpm and sounds almost stock from there with as far as I can tell little volume difference at high revs. That works for me. It's a daily driver so I didn't want a noisy system. Installation was fairly easy with the hangers being the biggest pain. I recommend using a lube some sort, especially on that bugger above the rear suspension. My only complaint is that the tip has some very light surface rust after a few months of winter salting. I'm in the process of turbocharging, and I'll update if there is any change in the sound or volume.
 

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Just won a HKS on ebay for stupid cheap. Look forward to info on fitment and a sound clip soon.
 

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So the HKS does fit on a duratec. Kinda anyaways, the last hanger had to be fliped 180 but other than that its good. The gas tank issue wasnt that bad still have some small clearance and the front pipe fits the stock cat location.:)

So far after about 60 miles the sound is meh. Need to get the cat back off the car and a header back on it to see how I like it.
 

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So the HKS does fit on a duratec. Kinda anyaways, the last hanger had to be fliped 180 but other than that its good. The gas tank issue wasnt that bad still have some small clearance and the front pipe fits the stock cat location.:)

So far after about 60 miles the sound is meh. Need to get the cat back off the car and a header back on it to see how I like it.
Flipped 180? My HKS required no such fitment modification.

Is this a Zetec or SVT system?

For how quiet you are describing id have to imagine it's the under axle Zetec 2 1/4inch system. As that is super quiet.

If it's that quiet it should sound VERY good with a header. Having a quiet exhaust with stock cat is not something I would consider bad.

- Drew
 

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Yep its the under axle zetec system. Well I'm not to sure how the last hanger was originally, when I got the Roush one a few years ago it came with a new hanger for the Roush bumper. I may have put it on facing the wrong way to begin with. :lol:

Just went out and made a sound clip that I'll be putting into the exhaust video thread here in a min. Have to say it is super quite and almost unable to hear it in the video when making a uphill 2nd gear pull from 1000-7600rpm. Can't wait to get the cosworth header back on the car. Hate this lack of get up and go the stock cat has.
 

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Yeah. The Zetec system is basically a deep near silent tone.

They meant that system to be coupled with a catless header or high flow cat and kept it silent.

I look forward to the sound clip and a header install. Congrats on the quality system.

- Drew
 

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Great info! I have a question on making them work for the wagon (hopefully one of the other wagon guys can chime in as well) - I'm looking this summer to get the FSWerks stealth for my wagon - would a regular exhaust shop be able to tackle welding in an extension piece between the muffler and the tip? How much longer does it need to be to fit well? I'm also assuming those numbers posted are coming from a car without an aftermarket header, correct?! I only ask because I'm looking into that as well.
I may be a little late, but I have a stealth system on my wagon. You just need 6 inches of .065 wall stainless tubing and a 2.5 inch band clamp. That extends the tip about 3 inches past the bumper. You will have to make a new rear hanger from stainless rod for the rear. The hanger on the stealth system came right at my trailer hitch. Good luck if you havn't tried yet.
- Jim
 
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