When creating a custom exhaust system, the emphasis is typically placed on pipe diameter and layout; however, just as crucial is the sound. Two components that are frequently confused or neglected when it comes to sound control are resonators and mufflers.

At DarkLight Fabrication, we assist all sorts of performance aficionados throughout Colorado in obtaining the power and the tone they desire—without the drone, rasp, or any unwanted noise. So let’s go through the differences between a resonator and a muffler, and whether or not you need one or the other or both in your build.

What Is a Resonator?

A resonator is a component of an exhaust system that behaves like a tuning fork. It uses the principles of acoustics to smooth out—and sometimes enhance—the sound of the exhaust. Without a resonator, the exhaust system can produce a very loud, obnoxious, and droning sound. A properly designed and placed resonator can help you avoid that unfortunate outcome.

Key traits of a resonator:

• Minimizes bothersome sound frequencies (without affecting overall loudness)

• Helps maintain a smooth, deep tone.

• Typically situated at the midpoint of the pipeline.

• Does not significantly limit exhaust flow

What Is a Muffler?

An exhaust system's overall loudness is not its true volume. This might be a little confusing or counterintuitive, but hang with us a minute. The muffler is what keeps the exhaust system from being excessively loud, not the volume control on your stereo. The better a muffler is at its job, the less sound comes out of the exhaust pipe when the engine is running.

Key traits of a muffler:

• Lowers total sound output.

• Available in many tone styles: aggressive, mellow, deep, etc.

• Typically situated at the back end of the automobile.

• Might introduce slight flow restriction (depends on design)

Do You Need Both a Resonator and a Muffler?

It depends on your set up and your goals. You might need both if:

• You want a clean tone without the system being too loud

• A turbo system or high-compression naturally aspirated (NA) engine that is prone to rasp means you're running one of two setups in which these suggested problem-solving fixes will most likely help.

Of course, those are not your only two options, but they are among the most common causes of engine rasp. If you're experiencing pervasive poke noises that are more than a harmonic phenomena or sound waves behaving badly, then it's time to fix your setup.

You might only need one or the other if:

• A more powerful or unrefined sound is desired on your part.

• You're constructing a vehicle that can only function on a track.

• You accept the amount of sound produced but wish to level out the tone (just the resonator).

• You prefer to keep things on the down-low but are not concerned about the rasp that comes from a vehicle with only a muffler.
  

At DarkLight Fabrication, we can adjust your exhaust configuration to suit your engine, turbo arrangement, driving style, and personal auditory taste. Whether you want it to be quiet but with a low rumble, or to hell with the decibel police, we'll set up the right combo for you.

What We Recommend

For the majority of street cars with turbocharging, we suggest using good oils with the following characteristics:

A mid-pipe resonator to quell vibrations.

A free-flowing muffler in the rear to control overall volume.

You get a clean sound, better drivability, and an efficient system — especially with the standard TIG-welded mandrel bends and 304 stainless tubing we use in every custom build.

Let’s Build Your Perfect Sound

Sound is unique to each individual. If your desire is for a smooth purr, or perhaps a full-blown scream, we can construct the system that delivers your exhaust tone with no drone, no buzz, and no compromises.

[Reach out to us for a tailored estimate], or pop into our shop in Denver to discuss the possibilities for your project.

Regarding automotive performance, few platforms have grabbed the hearts of enthusiasts as have the Diamond Star Motors (DSM) vehicles, particularly the 1G and 2G models. At DarkLight Fabrication, we comprehend the enthusiasm that pushes DSM owners to search for custom solutions for their turbo exhaust manifolds, downpipes, and exhaust systems. In this blog post, we will dive into the history of the DSM 1G and 2G, and we will cover why these platforms are still such a popular choice among car enthusiasts today.

The Birth of the DSM: A Brief History

Mitsubishi Motors and the Chrysler Corporation collaborated to produce the DSM, a series of cars that were sold as sport compacts during the 1990s. From 1989 to 1999, the DSM shared a platform with three different cars: the Mitsubishi Eclipse, the Eagle Talon, and the Plymouth Laser. Although these cars differed in some styling details and in the number of cylinders in their engines, they were nearly identical under the skin. All three came standard with a turbocharged engine that displaced 2.0 L (122 cu in).

The first-generation Diamond Star Motors (DSM) vehicles, released in 1990, were revolutionary for their time. They offered a combination of lightweight design, all-wheel-drive (AWD) options, and turbocharged power. I was particularly enamored with the AWD models—the Eclipse GSX in particular—for their impressive traction and handling.

Introduced in 1995, the second generation—2G—had even more updated styling and better performance features. The models comprising 2G, which included the Mitsubishi Eclipse, as well as the Eagle Talon and Plymouth Laser, continued to make use of the 4G63 engine. This time, however, the folks at Mitsubishi and Chrysler turned the wick up on that engine, and it made even more power and torque than before. The 2G Eclipse GSX and GST models did what the 1G models had done: they became icons of the performance generation.

Why DSMs are Sought After by Enthusiasts

1. Performance Potential

Car enthusiasts cherish the DSM platform primarily for its one overarching attribute—"incredible performance potential," the Federal Register states. The reason is simple: It pairs a robust turbocharged engine with a lightweight chassis. That combination makes it easy for the first two generations of these cars to reach high power levels with just a handful of basic modifications; the platforms in question are the 1G and 2G Eclipse. At DarkLight Fabrication, we create custom turbo exhaust manifolds and downpipes for those chassis to help unleash their performance.

2. Tuning Flexibility

The DSM platform is celebrated for its tuning adaptability. With a vast assortment of aftermarket components accessible, aficionados can readily tweak their rides to fit their precise specifications. From beefed-up turbochargers to one-off exhausts, the make-it-better options are nearly limitless. At DarkLight Fabrication, we partner with DSM owners to conceive and execute around the vehicle solutions that make them scream undying praises for our rig's performance.

3. Community and Support

The DSM community is one of the most fervently loyal and constructive car communities there is. Car enthusiasts in this niche share their expertise on online forums and social media with incoming community members. This allows new members to catch up, get involved, and take part in our cars' voices, sounds, and shadows as we drive them day, night, and everywhere in between. This is the Digital Shadows Mitsubishi community.

4. Classic Appeal

The appeal that the 1G and 2G DSMs have with car enthusiasts is almost a classic one. Many owners enjoy the trip down memory lane that the nostalgic design provides when they get behind the wheel. And the raw driving experience that these cars deliver certainly doesn't hurt their desirability. They occupy a unique place in automotive history. In no small part because of the above, the demand for these models seems to be climbing, too.

Custom Solutions at DarkLight Fabrication

DarkLight Fabrication comprehends the distinctive requirements of DSM owners. Our cohort of adept fabricators concentrates on rendering specialized exhaust solutions that are personalized to each automotive specification. If turbo exhaust manifold, downpipe, or complete custom exhaust system is on your to-do list, you are better positioned to see that project through to its upping-the-ante finish with products from DarkLight.

The automotive performance industry is where we are and where we want to be. Our dedication to quality and customer satisfaction is what sets us apart from our competitors. We take our craftsmanship very seriously, making sure that every piece we create meets our very high standards. If you order from us, you can rest assured that your DSM will not only perform at its very best but also look good doing it.

Conclusion

The 1st and 2nd generation DSM platforms have made quite an impression in the automotive world. With their performance potential, tuning versatility, and straightforward charm, they have garnered a dedicated following of enthusiasts. Here at DarkLight Fabrication, we exist to render that following all the more justified by providing custom fabrication solutions that help you, the DSM owner, realize the oft-unforeseen possibilities held by your car. Whether you're a seasoned veteran or are just now venturing into the sometimes bizarre, always interesting world of the DSM, we invite you to explore those possibilities with us.

The discussion surrounding turbo manifolds, whether cast or fabricated, has been going on for years. Both styles technically "do the job," but when you look at performance, reliability, and customization, the difference is like night and day. That’s especially true if you’re building a car that’s more than just a daily driver. Here at DarkLight Fabrication, we build fully TIG-welded, fabricated manifolds from 304 stainless steel — and here’s why.

What’s the Difference Between Cast and Fabricated Manifolds?

The cheapest and most common way to make an intake manifold or exhaust manifold is to use a mold. The mold can be made quite quickly and cheaply, allowing you to churn out lots of parts. So, cast manifolds are pretty much your go-to option when you want an intake or exhaust manifold that doesn't cost an arm and a leg. They are also the most widely available option.

Manifolds that are not made by gas tungsten arc welding (TIG welding) are made by hand using pre-bent pipe made mostly of stainless steel. They are carefully cut and formed using many hand tools. Then they are assembled with a variety of fasteners and welded with enough different types of welding that they really should be called a "manifold assembly" instead of a "manifold" for the engines to which they are attached.

They may have the same function, but that's where the commonality stops.

The Downside of Cast Manifolds

1. Cracking and Heat Fatigue

Nature makes cast iron brittle, and repeated heating and cooling cycles can reduce its lifespan, especially in high-boost, high-temperature turbo applications. So it is not uncommon for cast iron turbo manifolds to:  

•  Crack at the collector or flange  

• Warp with time  

• Fail when subjected to intense heat and vibration  

By contrast, a stacked-tube, welded, stainless steel manifold would be much more likely to:    

• Endure the conditions that make a cast iron manifold fail  

• Survive for a longer operational lifetime  

And a stacked-tube, welded, stainless steel turbo manifold can be made to fit the same applications as a cast iron manifold. 

2. Poor Flow Characteristics

For mass production, not flow efficiency, most cast manifolds are designed. The internal runners usually are: Short and stubby. Rough inside. Designed for packaging, not performance. Exhaust flow is turbulent, which means that the engine may not reach the power levels desired. In contrast, a fabricated manifold will feature smooth, equal-length runners that help your turbo engine achieve peak performance. 

3. Limited Fitment and Customization

Manifolds come in a cast form—no adjustments, no alterations from the standard, no chances of re-routing for your non-standard application. And, if you have a very tight engine bay, are going with an alternative forward-facing setup, or have a turbo that's placed anywhere else from standard, you need a fabricated manifold. Here's the kicker: when you go fabricated, you kinda get to choose and design the layout of your turbo system—around all of these factors: 

- Custom motor mounts 

- Relocated accessories 

- Hood clearance 

- Turbo size and position 

It's your build, your way.

Why Fabricated Manifolds Win

1. Designed for Flow and Performance

Every runner is meticulously shaped to direct airflow as smoothly as possible, reduce restriction, and feed the turbo as efficiently as can be done. Equal-length runners (where possible) and smooth transitions equate to: Faster spool More consistent boost Increased horsepower.

2. TIG-Welded for Strength and Beauty

We weld all our TIG manifolds by hand using 304 stainless, ensuring: Clean, strong welds with full penetration, no internal slag or spatter, a finish that looks as good as it performs. There’s a reason racers and serious builders choose fabricated manifolds — they hold up and they work.

3. Fully Customizable

It doesn't matter if you want: V-band or T4 flange, wastegate priority routing, top-mount or bottom-mount turbo, or twin scroll configuration; we can build it exactly how your setup needs it — not how a parts catalog thinks it should be.

The Bottom Line: Custom Wins Every Time

A cast manifold might work fine with a stock turbo at 8 psi. But if you're running serious boost, pushing high EGTs, or just want the best performance per dollar, a fabricated turbo manifold is the way to go. At DarkLight Fabrication, we build manifolds to match your power goals, space constraints, and turbo setup, using only 304 stainless steel, TIG-welded. Hand-built. Performance-engineered. Built to last.

Ready to Start Your Build?

We can build the manifold that makes your project possible, whether you're after a 400whp street setup or a 1000hp track weapon. [Request a quote today] or check out our custom manifold gallery to see recent work.

If you’ve upgraded your turbo or are planning to, one of the most overlooked power-adders is right under your nose — the downpipe. Too often dismissed as merely an exhaust component, an essentially unregulated downpipe—"custom" or otherwise—can release serious horsepower, torque, and drivability. Here’s how.

What Is a Downpipe, and Why Does It Matter?

The downpipe connects the turbine outlet of your turbocharger to the rest of your exhaust system. It's the first exit path for hot, high-pressure exhaust gases after they pass through the turbo.

Factory downpipes are typically:

• Narrow in diameter

• Filled with restrictive bends or kinks

• Often include catalytic converters, resonators, or flex joints that limit flow

These restrictions create back pressure, and in a turbocharged setup, back pressure = lost power.

How a Custom Downpipe Increases Horsepower

1. Increased Exhaust Flow Turbo performance depends on exhaust flow, but not just any exhaust flow. Since the turbo relies on exhaust gases to drive it, the gases must flow smoothly and quickly from the engine to the turbo charger, and then from the turbo to the atmosphere. A downpipe must be designed to do this, the better to make the turbo better. A downpipe must have a large enough diameter; that’s commonly 3 inches or more. A downpipe must have enough length; too short or too long, and the turbo won’t be happy. And a downpipe must not have any parts that would bend the exhaust flow, nor any parts that would reduce the flow, which means no flapper valves, exhaust ports, or other funny business.

2. Less Back Pressure = More Turbo Efficiency The fewer obstacles your exhaust gases encounter, the easier it is for your turbo to do its job. A downpipe with high flow after the turbine wheel significantly reduces back pressure, which: Delivers a faster spooling turbo. Produces a turbo that makes boost more effectively. Causes a turbine to work less and generate the same power.

3. Accessing More Potential with Custom Tuning A downpipe is just the start. It allows for flow, yes, but also for tuning. With better flow, your tuner can do more — do it safer — and get more from your engine: Increase ignition timing safely Run higher boost more efficiently Improve air/fuel ratio control You might see 15–30+ whp gains on a properly tuned turbo car with just a downpipe swap, depending on the setup.

Why Go Custom Instead of Off-the-Shelf?

An off-the-shelf (OTS) downpipe is designed for a stock setup — and often compromises fitment, weld quality, or material just to be universal. A custom-fabricated downpipe from DarkLight Fabrication is tailored specifically for: Your turbo kit Your engine bay layout Your goals for sound, clearance, and power And because we TIG weld all our downpipes using 304 stainless steel, you get: Superior weld strength Rust-free durability Clean aesthetics with exact routing We can also build in wideband sensor bungs, V-band or flange transitions, and provisions for heat shielding — all the little details that set a serious build apart.

Is a Custom Downpipe Worth It?

If you operate a turbocharged engine — indeed. One of the best_returns-for-your-buck modifications, especially when matched with calibration, is a custom downpipe. You’ll receive: An increase in the amount of horsepower and torque An even faster spool-up of the turbo Better throttle response An exhaust note that’s way more aggressive than stock And if you work on your engine and add future mods (like an upgraded turbo or different motor), a high-flow, totally reliable downpipe is the best thing to have at the beginning of your build.

Let’s Build Yours

At DarkLight Fabrication, we produce every downpipe with care and precision. Each piece is made from 304 stainless steel and is TIG welded in house. The routing, diameter, and specifics of each downpipe are matched to the customer’s individual setup. That makes us the go-to source for both serious street cars and those living on the edge of the law. Our downpipes are guaranteed to perform well under pressure.

The exhaust system is a crucial aspect of making the Subaru WRX or STI perform better. DarkLight Fabrication specializes in making high-quality turbo exhaust manifolds, downpipes, and custom exhaust systems that cater to the specific needs of these cars. In this blog post, we cover the basic, essential things that need to be considered when making an exhaust system for a WRX or STI. We focus on three main aspects: exhaust system clearance, exhaust system routing, and exhaust system sound.

Understanding Your WRX/STI Exhaust Needs

The rally-bred performance and turbocharged engines of the Subaru WRX and STI are known for their explosive power. Yet, to truly make these cars sing, an aftermarket exhaust is practically a necessity. The 2022 price tag for the exhaust options isn't a hard number to swallow, especially since the cheapest option doesn't sound anything close to the Subie rumble.

1. Clearance: The space you have in your engine bay and undercarriage is very important. An exhaust system that is designed well should have enough clearance so that it doesn't touch other components of the vehicle, even under aggressive driving or off-road conditions.

2. Routing: The way your exhaust goes from the turbocharger to the rear of the vehicle impacts back pressure and overall performance. Good routing can mean better efficiency and power output and fewer headaches over unwanted noise. Routing is mostly short, but there are some things you should really avoid doing.

3. Sound: Your WRX or STI may not be as quiet as a luxury car, but the auditory experience is part of the performance package. Different exhaust configurations produce different sound profiles: some cars have a fairly subtle growl at the rear when you throttle down; some have a bigger bang and a wilder sound; some are really loud, and some are a bit obnoxious.

Clearance Considerations

1. Underbody Clearance

When upgrading your exhaust system, it is imperative to first think about underbody clearance. Many aftermarket exhaust systems tend to hang lower than their stock counterparts, which can lead to us—unfortunate mortals who insist on driving our vehicles over bumps and uneven surfaces—scraping them or damaging them in some way. Here at DarkLight Fabrication, we promise that our custom exhaust systems will maintain the kind of clearance one expects of a high-performance exhaust system. Our systems have the clearance you need, the power you want, and the right look under your vehicle.

2. Heat Shielding

Turbocharged engines produce a considerable amount of heat, and their exhaust parts can get very hot. Ample clearance not only keeps the parts from touching each other but also lets heat dissipate effectively. We suggest that you use heat shielding in the vicinity of the exhaust when it runs close to anything that could be adversely affected by excessive heat.

That could anything up to and including the ecu. But in the area of concern to us, the exhaust is running close to the fuel lines and quite a bit of the engine wiring.

Routing Recommendations

1. Turbo Manifold Design

The exhaust system of your vehicle has many vital parts, and the turbo manifold is one of them. A good manifold is essential if you want to reduce turbo lag and improve throttle response. Your manifold needs to be very well designed and built to funnel the exhaust gas from the engine out to the turbo with minimum back pressure and turbulence.

2. Downpipe Configuration

Another critical area where routing plays a significant role is the downpipe. An unobstructed straight path from the turbo to the exhaust can reduce back pressure and improve turbo efficiency. For most WRX and STI applications, we recommend a 3-inch diameter downpipe to ensure that optimal flow. 

3. Cat-Back System

The section of the exhaust that runs from the catalytic converter to the rear of the vehicle is known as the cat-back exhaust system. A cat-back system that is properly routed should have few bends and restrictions, and it should have enough clearance that it can never touch the driveshaft, even during off-road operations. Our custom cat-back systems are made to hang like an art piece and work like a Rube Goldberg device. They flow exhaust gas smoothly, with no turbulence, right to the end of the tailpipe.

Sound Considerations

1. Exhaust Tone

The noise your WRX or STI makes is an essential part of the experience. Different exhaust setups yield different tones. A straight pipe does not only look the part (hello, horsepower), but it also practically guarantees the loudest, most aggressive tone. By contrast, if you want bigger, badder sound while still retaining a modicum of civility, we would recommend going with an exhaust that has suitable resonators and/or the kind of mufflers that sound better than the kinds of straight pipes that come with off-road kits.

2. Drone Reduction

A frequent problem with aftermarket exhaust systems is drone, which is a bothersome resonance that takes place at certain RPMs. To avoid this, we suggest using resonators or specific muffler designs that can reduce drone while still maintaining a sporty sound. We can help you choose the suitable components to achieve the ideal sound.

Issue: What happens when you don't use the right components?

Conclusion

Enhancing the performance and driving enjoyment of your WRX or STI can be best achieved by upgrading the exhaust system. At DarkLight Fabrication, we understand that clearance, routing, and sound are the big three when it comes to making your custom exhaust system. Our turbo exhaust manifold, downpipe, and cat-back system designs ensure that what you receive is not only well made and performing at the level of your goals but also is aligned with your personal preferences. We make the products that the other guys don't.

If you are prepared to elevate your Subaru WRX or STI to the next echelon, reach out to us today to confer about your exhaust specifications. Allow DarkLight Fabrication to liberate the latent power of your automobile!