What Are Exhaust Cutouts? How to Install, Maintain, and More

Did you know there is a way to customize your vehicle’s auditory experience? If you’re a fan of muffler modifications, then installing an exhaust cutout might be for you. This modification allows you to have more control over how your vehicle sounds.

What Are Exhaust Cutouts?

Exhaust cutouts are aftermarket modifications installed in the exhaust system that allow drivers to control the flow and sound of the exhaust gases. The cutouts provide an alternative path for exhaust gases to exit the system and bypass the muffler.

Opening the cutouts increases the vehicle’s exhaust sounds. On the other hand, closing them reroutes the exhaust through the muffler to minimize the noise.

There are two types of exhaust cutouts: manual and electronic cutouts. The former is operated by a lever or switch, hence the name. Meanwhile, electronic cutouts require a remote or switch, making them more convenient and easier to adjust.

There are three main advantages to installing exhaust cutouts. First, they increase power, as clearing out the exhaust imparts more horsepower. Second, they allow drivers to control how the exhaust sounds, increasing. Third, cutouts let you customize your vehicle as they provide a customizable auditory experience.

Are Exhaust Cutouts Legal?

Exhaust cutouts are legal in some states and illegal in others. It’s best to check with your local government or brush up on the state law or with the DMV, especially if you want to install exhaust cutouts.

For reference, exhaust cutouts are illegal in California. California Vehicle Code (CVC) 27150(a) prohibits the use of cutouts, bypasses, or similar devices in a vehicle’s muffler or exhaust system.

Things to Keep in Mind Before Installing Exhaust Cutouts

Besides the legality of exhaust cutouts in your state, some things to keep in mind before installing cutouts include the risks they present, the amount of maintenance they require, and choosing the proper size for your vehicle.

Cutouts Pose Risks

There are potential risks involved in installing exhaust cutouts, from the aforementioned legal issues to possible component wear. Make sure you know what you’re getting into before installing cutouts. For example, they create excessive noise and fumes, which could be dangerous to you and others.

Additionally, constantly leaving cutouts open can stress the engine and accelerate wear. And since cutouts can increase horsepower, it’s best to have tires that can handle the extra power so they don’t wear easily from the added torque.

They Require Frequent Maintenance

Exhaust cutouts require periodic cleaning and inspection, preferably at least once a month. This includes spraying the surface with penetrating oil to prevent carbon buildup as well as removing the cutouts for cleaning using a degreaser or brake cleaner.

Of course, the frequency of maintenance depends on how often you use the cutouts. The more you use them, the higher the chance of wear, requiring you to clean the cutouts more often.

You Need to Install the Proper Size

There are a variety of exhaust cutout sizes from 2.25 inches to 5.00 inches, with increments of .50 and 1 inch. Choosing the proper size is crucial, as installing a small cutout won’t be effective. Meanwhile, a large cutout can damage the exhaust system.

The proper size will vary depending on your specific year, make, and model. The best way to know what size fits your vehicle is to consult a professional since they’ll have the proper know-how and could even help you with installation.

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How to Install Exhaust Cutouts

Because there are two types of exhaust cutouts, there are also two ways to install them. Most of the tools overlap, so keep the following on hand:

• Exhaust cutout kit (manual or electric)
• Angle grinder/saw
• Welding equipment
• Clams
• Wrenches and screwdrivers
• Safety gear
• Wire and switch (for electric cutouts)

How to Install Manual Exhaust Cutouts

To install manual exhaust cutouts, follow the steps below:

• Step 1: Choose a spot on the exhaust pipe with enough clearance.
• Step 2: Use an angle grinder or saw to cut a section of the exhaust pipe.
• Step 3: Insert the cutout into the gap and use clamps to secure it in place. You can also weld it if you choose to.
• Step 4: Ensure all connections are sealed to prevent leaks.
• Step 5: Test the cutout by opening and closing it.

How to Install Electric Exhaust Cutouts

On the other hand, follow the steps below to install electric exhaust cutouts:

• Step 1: Choose a spot on the exhaust.
• Step 2: Mark the cut lines and cut the pipe using the grinder or saw.
• Step 3: Place the cutout in the gap and use clamps or a welding machine to secure it.
• Step 4: Route the wires from the cutout to the switch inside the cabin.
• Step 5: Mount the switch in a convenient location and connect it to a power source.
• Step 6: Test the system by turning the switch on and off.

Since installation varies, it’s best to check the installation guide written on the exhaust cutout kit. Some may require fewer or additional tools/steps, so make sure you follow the instructions properly.

You can also have a mechanic install the cutout, which could cost somewhere between $20 and $150, depending on the price of the cutout and labor fees. Having the cutout professionally installed is recommended if you don’t have the proper tools.

How to Maintain Exhaust Cutouts

Routinely cleaning the cutout is crucial to keeping it in top shape. To clean the cutout, turn off the vehicle and ensure the exhaust system is completely cool before accessing the cutout mechanism. Use a degreaser or carburetor cleaner to spray the sealing surfaces.

Afterward, spray WD-40 to lubricate the moving parts and prevent sticking. Cleaning a cutout varies per model, so it’s better to check for the manufacturer’s instructions for your model.