The goal was to go with a three inch stainless steel exhaust system. EuroSport Tuning sells a nice kit made by Ferrita in Sweden. I had installed one of the kits on Ted's 242T.

The EST kit is very well made.

It was designed to be installed on a 240 that has been lowered at least two inches. On such a lowered car, the system fits up high and tight under the floor boards. It is a system designed for a competition vehicle. where lowering and ground clearance are important. In that respect, The EST/Ferrita kit does the job nicely: fitting a considerably larger diameter exhaust system into pretty tight quarters.

Life on the street is not the same. The way roads, parking lot speed bumps, and driveways are built can beat the crap out of a lowered car and it's exhaust. Those who choose to lower their vehicle accepts those risks. The EST/Ferrita kit does a nice job of trying to minimize the dragging potential; but the configuration results in a very diminished axle clearance. A stock ride height will result in regular banging of the underaxle pipe by the axle tube.

So I faced a challenge with this kit [which I had only partly addressed and conquered with Ted's Turbo]: how to adapt and fit this very nice 3inch stainless exhaust system into a Volvo 240 Turbo that is NOT lowered, and will not be lowered [at least not in the foreseeable future].

Actually, there were three challenges to overcome:

...the aforementioned axle clearance issue because of the intended use on a lowered car;
...the lack of flex in the system, which can have two negative side effects: a droning noise in the system; and a great deal of unnecessary stress placed on the turbine housing and the manifold;
...the noise level is too much. A healthy rumble that is not illegally loud, but too attention-getting. It does not sound like a ricer wannabe; it is just.....not stealthy.

How I solved the problems is what this gallery is about.

The results were satisfying.
...The turbo and manifold are isolated from twist and stress.
...The axle clearance and ground clearance are now adjustable.
...The noise level is greatly reduced without diminishing the flow. It's like thunder in the distance: menace in the air; but you aren't sure where.

Stealth is the word.

I will be reworking Ted's system to incorporate the enhancements I developed on this install.