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Milltek Full System (including Hi-Flow Sports Cat) – MINI Mk1 (R53) Cooper S


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76.2mm Special – Includes bracket locator for 2004 cars

Milltek Sport has released an exciting new range of exhaust options for the tuner’s favourite; the R53 Mini Cooper S 1.6i Supercharged. As one of the World’s most experienced and accomplished exhaust manufacturers, Milltek Sport has huge experience in gaining the best sound and power improvements from the Mini and has used them to great effect in this system.

Milltek was one of the first aftermarket performance suppliers in the UK to gain access to the R53 upon its launch, quickly adding one to its development fleet. That fact, combined with the company’s huge knowledge of all BMW powerplants, has paid huge dividends. The design of the R53 exhaust offers superb power and torque gains, with a thoroughly ‘grown-up’ soundtrack.

Milltek quickly identified that exhaust tuning is critical on the Mini, due to the design of the punchy 1.6 litre engine and the relatively small size of the supercharger that is designed to deliver its power more like a normally aspirated engine. With these two factors playing a major part in the design process, Milltek’s engineers were keen to lower gas temperatures and optimise back pressure without inducing the ‘rasp’ that so easily occurs when tuning engines of this design. Needless to say, they managed it beautifully and the result is a note that exudes purpose, without droning or annoying at cruising speeds.

The system itself is based around a 2.5” (63.5mm) non-magnetic stainless-steel construction. Manufactured in Milltek’s Derbyshire factory, mandrel bending ensures a perfectly even diameter throughout and fitment apes the OE system to allow a myriad of fitment options and the ability to upgrade the system piecemeal, if required, to suit personal tastes or budgetary requirements.

A fully MOT-friendly system offers a 200-cell sports catalyst and comes complete with a custom manifold for optimum gains. After this, owners can opt for either a resonated or non-resonated centre section, depending on the exact note they wish to achieve. The cat-back system can be easily mated to the OEM cats if preferred, in order to reduce costs. The tailpipes feature custom-made 76.2mm trims that suit the Cooper’s valance perfectly.

Milltek recommends that the Sports Catalyst options be used in conjunction with software upgrades, fitted and mapped by a reputable tuner to achieve the best results and to prevent any warning or “Check Engine” lights being illuminated.



Milltek Sport have over 35 years of exhaust development which have led to them developing the ultimate ranfe of performance exhaust systems. Milltek Sport are at the forefront of tuning companies and owners ‘must have’ list in nearly 90 countries.

Milltek Sport exhausts are made using type aircraft grade stainless steel, known for it’s high quality and for being less likely to discolour (due to being anti-magnetic). All Milltek exhausts are designed and developed in-house in the UK.

With a Milltek Exhaust You Will Experience:

Transformation in Performance and Drivability.
Sharper Throttle Response.
Substantial Weight Saving Over OE Systems.
Precision‚ Quality Controlled Manufacture.
Highest (304) Aircraft Grade Stainless Steel.
Low Pressure Systems for Maximum Performance.

Additional information

Weight 22 kg
Dimensions 150 × 45 × 36 cm
Resonated or Non Resonated

Non Resonated (Louder), Resonated (Quieter)


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