Welcome to the world of trial and error!!
You basically need to find the sweet spot to you by removing cats and likely adding resonators in either the primary, secondary cat locations, or both locations depending on your taste.
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Originally Posted by e86nut
I'm also not too keen on doing like a bimmer-world x-pipe or any other catless x-pipe which would require a tune unless I have no other choice
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If you keep the X in the x-pipe in the factory location, it is not absolutely mandatory to get a tune if you go catless. You could make more power by getting a tune, but you definitely wont be slower!
Quote:
Originally Posted by e86nut
My initial idea was purely to cut out the secondary cat and either weld a pipe in its place or a resonator. Any opinions on if that would help? Or any other thoughts in general
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Removing secondary cats is one good place to start to add volume while still being emissions compliant and not having a check engine light on for "increased emissions." Getting rid of the cats is what is going to increase your volume the most, but at the expense of adding some rasp. Rasp isnt a bad thing as long as its "badass racecar rasp" and not obnoxious 350Z/G35/JDM 4cyl rasp.
Depending on your personal opinions of what resonators actually do (some say they tune unwanted noise out but do not affect the volume, some say they make the exhaust quieter and reduce unwanted high frequency noises), I think removing the secondary cats and replacing them with straight exhaust pipe is a good start but may not be enough increase for you.
Removing the primary cats and secondary cats and replacing with resonators will likely give you lots more volume with the least amount of rasp. I've seen several people rave about the "Six Resonator" x-pipe being great.
I personally have the Corsa axle back exhaust with just test pipes that remove the primary cats. It has great volume- its loud when you want it to be up top, sounds great when around town, but can also be quiet when cruising at light throttle. The possible downside are the addition of rasp and check engine light for emissions. I think the rasp is a really good rasp sound, but some disagree with any amount of rasp at all so
youtube.com/@thatwhitem4 if you want to listen to some in-car footage of my E92.