Exhaust Project

Starion_Turbo · Post by **Starion_Turbo** » Tue Nov 06, 2007 9:58 pm

Hey,

I'm undertaking the building of my own exhaust system real soon full 2.5" stainless, using mandrel bends, complete from turbo back.
Heres a shot of what I'm working with in the next few days:

Shiny :P, will add more pics as its built.

Post by **Alspos** » Wed Nov 07, 2007 7:54 am

Luverly :D

You doing the welding?

Love the dual chamber muffler thingy. Looks expensive. And twin tips should look good out the back...much more refined than a 5" cannon!

enthuzed · Post by **enthuzed** » Wed Nov 07, 2007 4:22 pm

Many projects can be exhausting.

Should come up sweet with that gear.

Starion_Turbo · Post by **Starion_Turbo** » Wed Nov 07, 2007 10:46 pm

Alspos wrote: You doing the welding?

Yes, Mig with Stainless wire and shield gas.

Alspos wrote: twin tips should look good out the back...much more refined than a 5" cannon!

I agree, the tips are angle cut whick looks even better than straight cut I reacon.
I'm tired of seeing every sports car fitted with a cannon, it is amusing when you see a cannon on a commodore tho rofl

I'm currently battling to keep the drill bits sharp enough to drill the 12mm 304 stainless plate for the dump pipe :(

silo · Post by **silo** » Wed Nov 07, 2007 10:54 pm

Starion_Turbo wrote:I'm currently battling to keep the drill bits sharp enough to drill the 12mm 304 stainless plate for the dump pipe :(

Reduce your point angle on the drill and it should cut better, also make sure it cuts! don't let it spin and rub on the stainless as it will work harden the staino :beer

Silas

thrash · Post by **thrash** » Wed Nov 07, 2007 11:58 pm

Starion_Turbo wrote: I'm tired of seeing every sports car fitted with a cannon, it is amusing when you see a cannon on a commodore tho rofl

Hey... bommodores can still produce some level of power.. what's funny is that a 5 inch cannon is now the stock muffler for every civic out there.. vtec isn't the same as a turbo you knobs :x

igottasicjb · Post by **igottasicjb** » Fri Nov 09, 2007 12:21 am

Should be a nice system, however you've spent around $500-600 bucks on polished stainless pipe and mufflers, why go and wreck it all by using a point and spray welder (mig). They are terrible welders. Stainless pipe should be tig welded. It is so much neater and looks a heap better. If you want a good quality affordable tig go to www.tokentoolroom.com/wsm200a.html and check out the wsm-200. It is a pulse DC inverter style tig. My mate has just bought one and the whole set up (welder gas and regulator) cost 790 bucks. Well worth the money for the quality of welds it can produce.

Just thought I might suggest it, not having a dig. I have done more stainless welding than you can poke a stick at and nothing looks better under the bonnet than a sexy stainless weld.
this was done whilst setting up a 550 dollar tig welder

a hint for dilling stainless, is actually increase the the cut angle on the drill bit and keep you drill rpm to about 500 rpm

Starion_Turbo · Post by **Starion_Turbo** » Fri Nov 09, 2007 1:16 pm

Hey

I managed to drill out the holes with a 118degree cutting angle also I used some cutting oil while drilling, still cuting out the turbo flange now with a carbide burr.

Y am I using a mig? Simply put it's because I have one to use. I'm not ready to spend more on a tig welder when I don't do a whole lot of work with steel.
The exhaust system is under the car anyway and I don't plan on showing it.

why'd I go stainless? reasonably priced and will last pretty much forever.

Sigma_turbzz · Post by **Sigma_turbzz** » Sat Nov 10, 2007 9:49 am

Why didn't you go 3" ?

It would be louder, but there is only torque loss, not torque gain with keeping the Exhaust small on turbos.

Starion_Turbo · Post by **Starion_Turbo** » Sat Nov 10, 2007 12:54 pm

The turbo exhaust inlet and outlet arn't even 2.5" turbo exit is 2.25"

Stock starion exhaust 2.25" with 2" dump pipe restricts down to even less than 2" at some points in the system (1 7/8" at dump pipe connector)
I reacon 2.5" will be plenty large enough for me as it is pretty much a straight through system with double chamber resonator.

Dump pipe picture on or by monday

Starion_Turbo · Post by **Starion_Turbo** » Sun Nov 11, 2007 5:39 pm

Pics of the dump pipe before final welding and cleanup:

It's longer as it sits back on an angle and has the 90 bend on the pipe not the actual system, theres a slight twist to it to clear bell housing etc.
Noticably lighter than the stock one.
The weldings not perfect, welding thin stuff aint fun but it's all in the name of experience.

bigd · Post by **bigd** » Sun Nov 11, 2007 6:53 pm

Looks good and will flow HEAPS better than stock. Can't wait to see the whole system completed! :beer

compressor · Post by **compressor** » Wed Nov 14, 2007 3:56 pm

sorry but i think it looks like chook shit look at all the slag :( get a pro to do it you spent good money on materials dont leb it up now

iXNAY · Post by **iXNAY** » Wed Nov 14, 2007 4:52 pm

compressor wrote:sorry but i think it looks like chook shit look at all the slag :( get a pro to do it you spent good money on materials dont leb it up now

its only because he is not using a tig welder but yes it doesn;t look the best but then again who is going to see it! aslong as it flows nicely and doesn;t leak does it really matter? he has already stated that he doesn;t mind cause know one will be seeing it

JD_Stazza_Brendan · Post by **JD_Stazza_Brendan** » Wed Nov 14, 2007 7:46 pm

He could probably clean that weld bead easily with a wire wheel.

Austarion

Exhaust Project

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