There are many companies that make bolt-on aftermarket headers and exhaust systems for prevalent Euros such as Honda Civics and Accords, but only a company like Bosal also has applications for the more "unusual" vehicles like the
Acura Integra, BMW, Mitsubishi Eclipse, Dodge/Plymouth Neon, Mazda, Volkswagen and the Ford Probe. So, when we decided to replace the exhaust system on our Project '95 Probe from the head to the tip, we chose Bosal's popular Brospeed bolt-on stainless steel performance exhaust system.
The history of Bosal dates back to the 17th century when the Bos family, originally blacksmiths from Germany, settled in the Dutch town of Alkmaar. Bosal's name derives from the Bos family name and the initial letters of their hometown Alkmaar. There Karel Bos (1896) started supplying the first exhaust systems in 1923. The present cfhairman of the Bosal Group, Karel Bos (1928), founded the first Bosal plants in South Africa in the 1950s where he started the first production facility for exhaust systems.
After establishing a manufacturing operation in Canada, Mr. Bos started production in Europe in 1968. Now, Bosal has 28 production plants in 17 countries and 45 distribustion centers and is regarded as one of the most important suppliers of exhaust systems in the world.
From the production of steel tube for exhaust systems, Bosal has expanded and developed its product ranges. The company has also become one of the foremost producers of welded steel pipes, tow bars, roof carriers, warehouse racking and cabs for industrial vehicles. Bosal products are now sold in more than 100 countries throughout the world and have become an OE supplier for GM, Rover, Jaguar, Saab and Audi.
Each Brospeed exhaust system is manufactured from T-304 stainless steel, and the headers are made of ceramic-coated mild steel. All Brospeed systems include polished chrome tips with a true rolled edge, high-quality MIG welded joints to prevent vibration fatigue, a low restriction muffler with tuned expansion chambers, a double-wrap, 20-gauge aluminized steel casing and double end caps. Mandrel tube bending ensures uniform tube diameter, header and exhaust tubes use 14-gauge mild steel, a unique "flex joint" absorbs front-wheel-drive (FWD) engine torque and vibration, and all connections are fitted with heavy gauge flanges, jig-drilled and ground to ensure gas-tight seals.
Brospeed's free-flow systems and headers are precision engineered and dynamometer-tuned for optimum engine performance. (Typical increases in engine output are from 10- to 15-percent when the systems are installed with headers and from five- to seven-percent with a "cat-back" exhaust only.) Using our previously established baseline figure of 89.5 horsepower to the wheels, we got approximately a nine-percent gain, boosting the 2.0-liter four-banger's output to 97.5 HP. Not bad for a smog-legal exhaust system. And, the improved looks of the stainless steel system and the cool chrome "can" (tip) are real pluses.
To determine just how truly "bolt-on" the Brospeed system really is, we called on performance exhaust builder/installer Lee Watts at Chino Valley Muffler (Chino, California). Lee made quick work of the project, bolting everything up with no cutting, welding or modifications necessary. The factory "flex pipe" was replaced with a simpler, more effective "ball joint" and donut between the header collector pipe and the catalytic converter (which remained in line). The oxygen sensor and EGR were retained on the new header and all factory rubber hangers were utilized. Gaskets, bolts and self-locking nuts are included and all systems are guaranteed for five years.
In a nutshell, Lee said of the system, "I'm impressed!" The fit and finish are flawless, and the ease of installation of everything was great. Because we were replacing the entire exhaust system as well as the header, Lee started at the rear end of the Probe. After watching him do the work, we'd have to agree, start at the tailpipe, not the engine. Take a look at the photos and you'll see just how simple it is to help your engine pass gas better with Brospeed.
 Project Probe gets the improved...  Project Probe gets the improved performance with a complete Brospeed exhaust system from Bosal. |
 The Brospeed header and stainless-steel...  The Brospeed header and stainless-steel exhaust system is a true "bolt-on" kit, and includes everything that you'll need to make quick work of the installation. |
 A variety of rolled chrome...  A variety of rolled chrome super tips (cans) are available to suit your tastes. |
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 Lee began the work by unbolting...  Lee began the work by unbolting and removing the existing muffler. |
 Spray lubricant will help...  Spray lubricant will help to take the rubber hangers off the exhaust pipes. |
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 Next the resonator and catalytic...  Next the resonator and catalytic converter are unbolted and removed. |
 The "cat" will be kept in...  The "cat" will be kept in line, so Lee gave it a visual inspection to make sure that the media was intact and the unit was reusable. |
 The factory "flex pipe" was...  The factory "flex pipe" was removed next. We won't need this part again. |
 The existing muffler (top)...  The existing muffler (top) and the larger, stainless-steel Brospeed unit. |
 The stock resonator and 2-inch...  The stock resonator and 2-inch connector pipes (top) compared to the larger Brospeed stainless-steel resonator and 21/4-inch. |
 The factory "flex pipe" (top)...  The factory "flex pipe" (top) is replaced with a "ball joint" type flex device. |
 While under the car, unbolt...  While under the car, unbolt the oxygen sensor from the stock header. |
 After disconnecting the negative...  After disconnecting the negative battery terminal, the air intake unit and the heat shield were removed from the engine. |
 The heat pipe must be unbolted...  The heat pipe must be unbolted from the stock header. |
 The stock header was then...  The stock header was then removed easily from the top. |
 The factory header (left)...  The factory header (left) doesn't compare to the ceramic-coated tuned Brospeed header/collector pipe. |
 Carefully remove any carbon...  Carefully remove any carbon buildup on the head (being careful not to gouge the aluminum) before replacing the steel gasket on the studs. |
 The header gasket was placed...  The header gasket was placed on the clean head and the car was raised again. |
 With the rubber engine shroud...  With the rubber engine shroud removed, Lee easily slipped the new header inplace on the head bolts. |
 The header bolts are installed...  The header bolts are installed and tightened evenly. Don't over tighten. |
 The heat pipe, oxygen sensor...  The heat pipe, oxygen sensor and EGR were then reinstalled in the new header. |
 There was no provision for...  There was no provision for attaching the factory heat shield, which we didn't mind because the new header looks so good. |
 The factory air intake unit...  The factory air intake unit was replaced and we moved back under the car. |
 The "donut" was slipped over...  The "donut" was slipped over the header pipe. |
 The connector pipe was then...  The connector pipe was then attached, using the provided spring tension bolts and nuts. |
 The catalytic converter was...  The catalytic converter was then bolted to the connector pipe, using the supplied gaskets. |
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 A small amount of gasket sealer...  A small amount of gasket sealer was applied to the paper side of the new gasket before attaching it to the rear of the "cat." |
 The new resonator and exhaust...  The new resonator and exhaust pipe unit was then bolted to the "cat" and hung, using the factory hangers. |
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 Finally, the new Brospeed...  Finally, the new Brospeed muffler and tip were hung and bolted to the exhaust pipe using the supplied steel gasket between the pipe and muffler. |
 The stainless-stell system...  The stainless-stell system looks great and is guaranteed for five years. |
 The larger Brospeed muffler...  The larger Brospeed muffler and rolled chrome tip (with a drain hole to prevent water damage) look and work great. |
 The system tucks up under...  The system tucks up under the car nicely but still visible for show. |