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Jeff, remember what I said yesterday about your car having an upper midrange punch to it? I'm pretty sure that's the reason why. As ears get old, they hear sounds differently.
I listened to the tone of all the cars as they passed by. Some were pleasing to the ear with a nice "purr" and some just set my teeth on edge. Mostly, it was the ones with the extreme upper midrange spike. Some had a metal on metal sound that was also a bit grating.
I'll bet if you can lower the resonant frequency of your car to give it a low mid peak, you neighbor will not complain as much.
Start thinking of your exhaust system as an instrument. What kind of metal is your system made of? Regular steel? Stainless?
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