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1997-2004 Corvette Billy Boat Fusion SS Exhaust System with Quad 4 Inch Round Tips

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Brand Logo Billy Boat
Part #: 648-827
Availability: This item ships direct from the manufacturer
   Normally Ships in 60+ Days
Fits Years:
  • 1997-2004
$2,599.99 This Item is Not Eligible for Promotional Discounts
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1997-2004 Billy Boat Fusion SS Exhaust System with Quad 4 Inch Round Tips

With unparalleled performance, sound and style our 1997-2004 Corvette Billy Boat Fusion Exhaust brings NPP technology to your C5.

The Fusion is a bi-modal Exhaust System, meaning it has two passages, or modes, that the exhaust can travel through the muffler. Each of the mufflers has two outlets, with one side having a butterfly type valve which allows the exhaust flow to be shut off, regulating which side of the muffler the exhaust flows. One side of the muffler is the "quiet" side, and one side is the "loud" side. The "quiet" side is a smaller, muffled and chambered tube, while the "loud" side is 3" tubing straight through.

The butterfly is controlled by a vacuum valve, which was built and developed completely in house. On the Z06 and the 2008 C6 Corvette with the NPP option, this valve is controlled by the ECU. The valve opens based on RPM and throttle position. Since the C5 Corvette has no option for the valve, we use the same vacuum kit and control as the C6 without NPP. The expertise at B&B is getting the "tone" right for your C5 Corvette, and we think they nailed this one. In the closed position, the tone is agresssive, but substantially quieter than the standard Bullet system. Open the valves, the overall volume and tone increases to the point of the classic Bullet exhaust tone.

  • Dual Mode Exhaust with Loud and Quiet Tones
  • All Hardware Included
  • Quad Round Exhaust Tips

Also known under these part numbers:

  • 1154
  • FCOR0150

Let our professional installers install this item for only $100.00

Mid America Motorworks offers installation services for a variety of restoration and aftermarket Corvette products. Our team is highly experienced in skilled, professional installation – let us do the hard work for you! Getting your Corvette back on the road or upgrading it to your personal taste has never been easier.

The Installation & Restyling Center is open:

  • Monday through Friday, 8 am to 5 pm CST
  • Saturday 8 am to 4 pm CST by appointment
  • Sunday by appointment

Relax and enjoy the MY Garage Museum and Retail Store while your upgrades are made, or on more involved projects, use our loaner vehicle, which is available on a first come first served basis. We can also provide assistance with booking local hotels at our corporate discount rate if you plan to stay here in Effingham, IL for a few days.

While under our care, your Corvette will be stored in a secure, temperature-controlled location, giving you peace of mind until you’re ready to take it back home. When your installation is complete, we also offer detailing services to get your Corvette ready to turn heads!

Schedule your Installation today by calling 800.500.1500 or emailing

FAQ’s concerning Billy Boat Exhaust Systems, Names and Tonal Evaluations

How do I make a decision on the type of sound I want for my Corvette Exhaust System?


Since an exhaust sound is heard somewhat differently by each person, we have attempted to classify all BBE exhaust notes by a Style Name that identifies the attributes of that specific system.


     FUSION Exhaust - NPP Controlled Bi-Modal - Aggressive when Open, Mild when Closed.

     PRT Exhaust - Aggressive Sound at Wide-Open-Throttle, Mild sound at cruise.

     BULLET Exhaust -  Aggressive Sound



What is a Fusion Exhaust System?


Billy Boat Exhaust has designed a Fusion NO-DRONE exhaust for the factory NPP and the non-NPP Corvettes. On C6 Corvettes with the NPP option, the butterfly valve in the exhaust is controlled by

the ECU. The valve opens based on RPM and throttle position. The expertise at BBE is getting the “tone” right for your Corvette, and we think they nailed this one.


Even in the closed position, the tone is deeper, louder, and more aggressive. Open the valves and the overall volume and tone increases to the point heads will turn when you drive up.


Add our 648-042 conversion control kit for Corvette models without factory NPP controls. The kits comes complete with all the wiring, remote switch, vacuum line, vacuum accumulator, and vacuum switch needed for installation. Can only be ordered with Fusion Exhaust Systems.



What is a PRT Exhaust System?


The Billy Boat Exhaust PRT C6 exhaust system is the latest control in Performance Resonance Technology from BBE. Completely redesigned and reengineered for the C6, the system is simple in design, though more complex in theory.


You can now have a mellow NO-DRONE sound at cruising speeds and a sport note when you’re tearing up the streets. It allows true straight through exhaust passage under aggressive driving conditions, though a mellow sound is emitted at cruising speeds thanks to the unique Purge Chamber.


Designed especially for the automatic, paddle shift and cars with headers, this Billy Boat Exhaust PRT system works purely on physics and adrenaline.


Increases of 15 hp and 14 ft lbs over stock.



What is the meaning of a Bullet Exhaust System?


Billy Boat Exhaust has created a deep, healthy exhaust note at low RPMs with an assertive muscle car roar on acceleration. Not for the weak at heart, the Bullet Exhaust System has quickly become the industry standard for a deep, aggressive muscle car sound for Corvettes.


You can see up to 18 rear wheel horse power and 17 foot pounds of torque from the Bullet. Billy Boat Exhaust’s boldest tip style and configuration insures the Corvette will scream “muscle car”.


What is a Cat Back Exhaust System?

The term “Cat Back” can be defined as the section of the exhaust system that runs from the outlet of the catalytic converter to the exhaust tips. A cat back exhaust system usually includes the pipes from the converter to the mufflers, the mufflers, and the exhaust tips.

A cat back exhaust is typically made up of rear-pipes, resonators, mufflers and a “style” and size of muffler tips. Depending on your Corvette’s year, model and location of catalytic converters, it can also include a mid-pipe and or a X-pipe.


What is an Axle Back Exhaust System?

The term "Axle Back" or rear section exhaust implies the exhaust system is located behind your Corvettes rear axle.  Corvette Axle Back Exhaust Systems typically replace the factory rear exhaust pipes, rear mufflers and muffler tips with an improvement in overall sound and appearance.

If the stock cat's can flow a large amount of exhaust gas without creating too much restriction, adding an aftermarket  "Axle Back" exhaust system should offer a nice increase in horsepower. 

Warranty for Billy Boat Exhaust BBE Products


Billy Boat Exhaust warrants its products, excluding catalytic converters, to the original purchaser of record and for the original vehicle on which the product was installed, against defects in materials and workmanship for the LIFETIME of the vehicle.


This warranty is void if the product was not installed properly on the vehicle, was installed on a vehicle for which it was not designed, or was removed from the vehicle on which it was originally installed and reinstalled on another vehicle. This warranty shall not apply to normal wear, cosmetic issues such as coatings and material discoloration, any product that was installed on a racing vehicle, installed improperly or contrary to Billy Boat Exhaust instructions, altered, misused, repaired, damaged from an accident, collision, undercarriage road impact or debris, or willful or negligent act. Any modifications to the product or its intended use voids the warranty. No person or representative is authorized to extend any warranties on behalf of Billy Boat Exhaust, other than the warranty expressed herein.


In no event shall Billy Boat Exhaust or any Billy Boat Exhaust Dealers or Distributors be liable for any loss, labor, inconvenience or damage…whether direct, incidental, consequential or otherwise. No person or representative is authorized to extend any warranties on behalf of Billy Boat Exhaust, other than the warranty expressed herein.


Billy Boat Exhaust shall have no liability for the cost of installation or removal of the defective product, the cost of labor or any additional parts required to complete the installation of the replacement product, towing or transportation costs, or return shipping costs. In no event shall Billy Boat Exhaust be liable for any direct, indirect, special, incidental or consequential losses and/or damages, including but not limited to interruption of business or loss of business or loss of profit or damage to related components resulting from the use of or inability to use the product, or any breach of warranty or any defect in the product, even if Billy Boat Exhaust shall have been advised of the possibility of such potential losses or damages.


Because sound is subjective, we do not warranty for sound. We offer various sound levels on most systems and encourage you to visit the extensive selection of videos on our website,, and our Distributor’s websites Please do not return your Billy Boat Exhaust product if you do not like the sound level.

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Stock or Aftermarket Exhaust: Which Exhaust is Right for Your Corvette?

Stock or Aftermarket Exhaust: Which Exhaust is Right for Your Corvette?

Corvette exhaust comes in a variety of options. From stock to keep your Corvette looking showroom-new to aftermarket to add more performance, exhaust can be as varied as the Corvette community. Mid America Motorworks takes a closer look at stock and aftermarket exhaust options to ensure your Corvette is running the system that's right for you.

Exhaust Manifolds vs. Headers

Corvette manifolds and headers are both designed to channel exhaust away from the cylinder heads and eventually out the back of the vehicle. Manifolds are made with a single piece that services all cylinders, while headers give each cylinder a dedicated pipe to eliminate back pressure.

Manifold Pros:

  • Price – Thanks to their utilitarian design, manifold cost is relatively low
  • Sound Reduction – Thick walls absorb some of the sound as exhaust gases collect inside the manifold
  • Original Fitment – Manifolds are stock on Corvettes and therefore are an easy bolt-on item

Manifold Cons:

  • Sacrificed horsepower and torque – The utilitarian design was built for cost savings, not performance

Header Pros:

  • Designed for ultimate flow
  • Designed for prime backflow pressure
  • Control where you want your power increase (high end or low end)
  • Add coatings to control heat dissipation
  • Lighter weight than manifolds
  • Increased horsepower and fuel efficiency

Header Cons:

  • Sound Decibel Levels Are Higher – may be too loud for cruising
  • Engine Compartment fitment may be tighter
Corvette Exhaust

H-Pipes vs. X-Pipes

The crossover pipe is the heart of any performance exhaust system. Bolted to the center of your Corvette, it balances exhaust impulses from both sides for smooth exhaust flow and a more efficient engine. Corvettes come stock with H-Pipes and can be upgraded to X-Pipes, but what's the difference?

H-Pipes and X-Pipes


An H-Pipe is shaped like the letter H, and relies on exhaust expansion to balance the cylinder banks. A section of tubing in between the main pipes provides an area for gases to expand into during exhaust pulses. Only a small amount of exhaust flows from one stream to the other as both sides push back and forth in the center section. Gains in performance are noticed from a low RPM and give the exhaust a deeper, old American muscle car tone.


An X-Pipe is shaped like the letter X, and allows the exhaust to flow down the path of least resistance. At lower revs, turbulence is formed as exhaust gases try to shuffle past a second column of gases coming from the other side. While producing more power than the restrictive factory system, the potential gains are not seen until higher RPMs are reached. This is where an X-Pipe stands apart from the rest. Exhaust gas is pushed out harder as the engine spins faster. The X-Pipe merges the turbulence into two uniform streams, for a smooth flow to the tailpipes. Both streams keep each other up to speed, which draws even more spent exhaust out the cylinders. X-Pipes provide a boost in horsepower and a higher exotic car tone.


When Corvette manufactures design a muffler system, cost is a big factor in determining the final style. The original system will provide great looks and function properly for years of road trips. However, there is a lot of room for improvement if you choose to put on a custom muffler system. One advantage of aftermarket exhaust is that you can tailor the system to meet your needs. Be sure to consider the following:

  • Decibel level – Mid America Motorworks has created an IAC Exhaust Rating Chart to help you choose the right exhaust based on tone during idle, acceleration and cruise.
  • Tone – Different brands usually have distinct tones. The tone that's right for you depends on your personal preference.
  • Tip Number – Corvette exhaust is available in dual or quad tips.
  • Tip Size – Personal preference is once again a factor in deciding muffler tip size. Tips can range from 2" to 4.5" and can alter the idle tone of your exhaust.
  • Tip Shapes & Color – Complement your Corvette's exterior with custom tip shapes and polished or black finish options.
Exhaust loudness chart
C5 exhaust

NPP Exhaust

GM designed the NPP Exhaust Option to allow 2008 and later C6 Corvette owners to experience louder exhaust notes at full throttle. NPP simply refers to the option code. Mid America Motorworks has developed an NPP Bimodal Switch for 2008-2013 C6 Corvettes that allows drivers to enjoy the louder note across the full RPM band. A computer-controlled valve in the exhaust system opens during acceleration and closes during cruise. The NPP Exhaust switch allows you to open the valve on command with the flick of a switch.

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