Latest Mod: B&B Fusion Exhaust

[C5pilot]

First, I want to thank Tony & Rose for helping me with the install. Their assistance was invaluable and made the install fun (the hot tub afterwards didn't hurt either).

The BB Fusion is very similar to the GM NPP system but is definitely louder in both modes. It also comes with a wireless FOB activated switch. In the closed mode it's slightly louder than the B&B Route 66 mufflers. In the open mode it's almost as loud as Bullets! There IS heavy drone in the open mode between 1700-2000 RPM but somewhat less when closed. So highway driving should be easier on the ears.

The system includes EVERYTHING needed except the tools and manpower. The tubing and wiring is precut to the correct lengths with all connectors installed. The FOBs are preprogrammed so it worked the very first time. The extent of the wiring includes pulling a fuse, attaching the ground wire, and pushing 2 connectors together.

The wires are easily run underneath the passenger side molding to the right rear hatch where you drill a hole to connect to the system. You pull the vacuum hose from the right side of the engine bay through the torque tube tunnel and over the Axel. You DO need to drill 5 holes total but they're all through plastic, very easy, and nothing that needs high precision.

The fit and finish of the system is extraordinary. Perfect fit with no alignment issues, we basically tightened them where they hung naturally. I'll check them again after some heat cycles to see if they move, but they look perfect right now.

The toughest part of the upgrade was opening the small vacuum port behind the intake manifold which supplies the vacuum to operate the bi-modal system. You can't see it, you have to feel around and make sure you're breaking off the right piece to open up the unused port.

It's not in the instructions but if you didn't want 4 screws visible in the wheel well and you don't mind losing about half of a storage compartment, you could simply lay or mount the components inside and drill holes hidden underneath. My emergency tool kit fits perfectly inside so I mounted mine as instructed. I'll paint the heads of the mounting screws black or maybe find some black plastic push pins to hold the system behind the wheel well.

In closing, I have to say, B&B put a lot of effort into making this a high quality system. From the HIGH polished exhaust to the included wire ties, they set out to make this the highest grade exhaust upgrade available. I'm impressed. Here's a link to their site...
http://www.bbexhaust.com/car/corvette/fusion/index.php

[Glennm27]

Nice write up Joe. I'm anxious to see and hear them. ;bc

[Silver O Six]

I put the B&Bs on the Z over the winter. I am thrilled. Everything you
mentioned is the same for me. Enjoy em! ;aw

[C5pilot]

Nice write up Joe. I'm anxious to see and hear them. ;bc

I hope to make the club meeting Thursday night for anyone who'd like to hear/see them.

I put the B&Bs on the Z over the winter. I am thrilled. Everything you
mentioned is the same for me. Enjoy em!

Yeah, I've already seen a drop in MPG and in radio use. Did you replace an NPP system with the B&B? I'd like to know how much difference between them.

[Mike Campbell]

Joe, the mileage drops because you're on it more just to listen to the sound. It'll get better when Chris drives. :D By the way, did you get the sweet oval tips? ;tt

[Silver O Six]

I hope to make the club meeting Thursday night for anyone who'd like to hear/see them.



Yeah, I've already seen a drop in MPG and in radio use. Did you replace an NPP system with the B&B? I'd like to know how much difference between them.

I (got the one's with the NPP system. There is very little difference.

Maybe not worth the extra $$$

Yea, I am going to take the radio credit on my next car....

[C5pilot]

Joe, the mileage drops because you're on it more just to listen to the sound. It'll get better when Chris drives. :D By the way, did you get the sweet oval tips? ;tt

Nope, I got the 4" round, they fill in the opening nicely.

[C5pilot]

UPDATE: Fusion goes bye-bye

Since the initial install of the Fusion exhaust system some changes have taken place. The exhaust began getting louder in the closed mode and the drone became more annoying on the highway. Around town was no problem because you quickly accelerate out of the drones rpm range.

By August it was downright irritating, so I contacted B&B and setup an appointment to meet Mark Fowler at Carlisle. He took a drive with me and agreed the drone in closed mode was too excessive and claims the problem is strictly with the A6's. So he asked if I'd like to try a copy of the original design with larger mufflers. He said M6 customers complained it was too quiet and changed to smaller mufflers. I said sure. In the mean time, I installed headers and since the Fusion was so loud already it didn't really change the sound that much.

B&B shipped the replacement set just in time for Corvettes on the Boardwalk. Tony and I installed them and the first thing I noticed was there was more difference at idle between open & closed, that's good. But sadly there was still drone in closed mode. On the bright side it was a shorter rpm range but once I hit the turnpike, it was clear... the drone was RIGHT in the middle of cruising RPM and even worse than before (probably due to the headers). It got so bad on the way home from the shore that I had to plug my ears with tissue paper just to keep from veering into a guardrail just to end it all.

To put it into perspective, do you remember the movie Dumb & Dumber? Imagine the part when they're driving cross country in their "dog" van and Lloyd (Jim Carrey) asks "Wanna hear the most annoying sound in the world?" THAT sound he makes doesn't even come close to a droning exhaust that just POUNDS you with low frequency sound waves for hours on end. If we used that sound to drive the insurgents from Iraq, all of our troops would be home right now (or in Afghanistan).

So I called B&B to report back and Mark offered to keep trying but the next solution of adding resonators in the pipes wouldn't work because they'd interfere with the headers. He graciously offered to work with Corvettes of Houston (the vendor I used) to get me a refund and promised to call me if they make any breakthroughs for the A6's.

So as it stands, I put the OEM mufflers back on and they sound pretty good with the headers (still too quiet but above 3000 they roar pretty good). With any luck I'll get the 2 systems shipped back this week and hopefully get a full refund thanks to the good will of B&B and CoH. It's a shame because it's a beautiful high quality system that sounds great except for a couple hundred rpm range on the A6. I'm going to miss them except on the highway.

[carboman]

Nice they stand behind their product. All I can say is CORSA! Skip the NPP part. No drone at all, loud when you hammer it and nice and mellow at crusiing speeds.

[Glennm27]

Joe,
I have my OEM Z06 catback that I replaced with Corsa's if they'd interest you at all....

[Last Canadian Exit]

Glenn, does the OEM Z06 cat backs sound better than stock C6's? I never got a chance to hear them on your car!

[Glennm27]

Glenn, does the OEM Z06 cat backs sound better than stock C6's? I never got a chance to hear them on your car!
I guess so. :confused: The OEM Z06 do have the open/closed vacuum setup on them.. They are a larger OD that the standard C6 so they need some type of reducer to fit up.

[Last Canadian Exit]

Ah, gotya! Thanks! If you could get them retroed, they probably would work okay.

[C5pilot]

Joe,
I have my OEM Z06 catback that I replaced with Corsa's if they'd interest you at all....

I'll do a search to see what's involved retrofitting it. Send me a link if you find something.

[carboman]

I'll do a search to see what's involved retrofitting it. Send me a link if you find something.

All you need to do to is either weld a 2.5" to 3" adapter to your X pipe or replace your X pipe with one that ends in 3" pipe. Any competent muffler shop could make the adjustment.

[C5pilot]

My Kooks have a built-in X-pipe. I won't be modding that in case I don't like the sound of yet another exhaust. I'd probably be better off waiting to find someone selling their used NPP. Those are 2.5", correct?

[carboman]

My Kooks have a built-in X-pipe. I won't be modding that in case I don't like the sound of yet another exhaust. I'd probably be better off waiting to find someone selling their used NPP. Those are 2.5", correct?

2.5" is correct!

[Richy]

Joe,stop whining you candya** & turn up the radio.

[C5pilot]

Joe,stop whining you candya** & turn up the radio.

There's a radio? :eek:

[Silver O Six]

Joe, I am still very happy with the B & Bs. Yes, there is some drone
but higher revs quickly solve the problem. My hat is off to you for swapping out exhaust systems;at I wish you the best of luck in finding what you want. Keep us posted!;aw

[C5pilot]

What RPM does your car cruise at 65-70mph? Have you spent many hours on the highway? From what I've heard it's not a problem for sticks. I'd never have guessed the cars cruised any differently but for whatever reason, only some A6 owners complained about drone while closed. Maybe Richy is right, and A6 drivers are all candy*****. But that's just silly, Richy couldn't be right.

The alternative was to drive on the highway in 5th gear, and that just wasn't an acceptable solution, nor did they even suggest it. Being one of the most expensive systems available, I'm VERY glad they gave me the option to return it. Must be my charming personality.

[Richy]

....................... Being one of the most expensive systems available, I'm VERY glad they gave me the option to return it. Must be my charming personality.

More likely they hated to hear a grown man cry.

[Last Canadian Exit]

Would putting Z06 cat backs onto a base C6 improve its performance at all? I don't have NPP and I am not going to be getting a set of Corsa's or anything anytime soon, so I am curious.