Drwojo Posted March 20, 2010 Report Share Posted March 20, 2010 Well I will start with that I am not a professional welder. I was given some 2 3/4 custom sized exhaust pipe from a friend for helping pull the motor on his STi. There has always been the argument between 2 1/2in and 3in exhaust, so I guess I will have the best of both??? maybe?? I purchased a chop saw from Harbor Freight for 50 bucks. Why not? Now I can cut metal whenever I see fit. I was running the stock downpipe to a poorly bent pipe that a friend welded to the flex pipe. I decided to do pie cuts and weld together my own downpipe. It is noticeably lighter and dose not have 4 different size changes in it now. Flame suit on! http://i160.photobucket.com/albums/t168/food28/DSC02830.jpg http://i160.photobucket.com/albums/t168/food28/DSC02826.jpg http://i160.photobucket.com/albums/t168/food28/DSC02822.jpg http://i160.photobucket.com/albums/t168/food28/DSC02821.jpg http://i160.photobucket.com/albums/t168/food28/DSC02829.jpg http://i160.photobucket.com/albums/t168/food28/DSC02823.jpg http://i160.photobucket.com/albums/t168/food28/DSC02828.jpg http://i160.photobucket.com/albums/t168/food28/DSC02827.jpg Not the worlds best welds but I learned a bit. I left my mask on way too dark and couldn't see what the hell I was doing for the first half of the welding. Once I adjusted the shade I started to lay out nice beads. What you see is the yuckier of the group. Now to drill a hole and install my Innovate wideband and be done with my garge project. O and yes it is 5:13 am and I am just getting done. I started around 1:30. Link to comment Share on other sites More sharing options...
TainterRacing Posted March 20, 2010 Report Share Posted March 20, 2010 whats it look like on the car? Link to comment Share on other sites More sharing options...
tsiconquest88 Posted March 20, 2010 Report Share Posted March 20, 2010 honestly, what your doing is great, and be interesting to see what you find. 2.5 really is better than 3" between the 2 from my builds. 2 3/4 might be the cheeck spot lol. Link to comment Share on other sites More sharing options...
vbrad511 Posted March 20, 2010 Report Share Posted March 20, 2010 (edited) Not as pretty as some, but much better than what I've got, and WAY worth the $50 and the little time you've got in it so far. One thing you'll absolutely need to add to the DP is a flex pipe. If you mount it solid like it is, even with a few hangers along the way, there won't be any flex off the manifold and you'll be ripping exhaust studs out of the head. I just did a quick search on Ebay and couldn't find 2 3/4, but you can get 3" and either space up or weld up the difference. http://cgi.ebay.com/ebaymotors/3-X-8-Stainless-Steel-Exhaust-Muffler-Flex-Pipe_W0QQcmdZViewItemQQhashZitem439d88156dQQitemZ290405750125QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories You'll notice no actual flex in the stocker, but the flex is achieved by the two bolts after the precat with the springs on them. They allow the lower pipe to give while it moves on the donut between the pieces. Edited March 20, 2010 by vbrad511 Link to comment Share on other sites More sharing options...
Elkidmino Posted March 20, 2010 Report Share Posted March 20, 2010 This will be exiting after the front tire. I can't wait to hear this ridiculousness. Link to comment Share on other sites More sharing options...
Drwojo Posted March 20, 2010 Author Report Share Posted March 20, 2010 You'll notice no actual flex in the stocker, but the flex is achieved by the two bolts after the precat with the springs on them. They allow the lower pipe to give while it moves on the donut between the pieces. I may get one of these. I kept looking to see how I could mount something like the stock knuckle thing that was going on. I had been running the open downpipe for a while and thought to just do it right. It did sound really good. I hope this one has a little more gurth to it! When it is mounted it hangs with about 1 1/2 of space form the framerail. With the motor rocking I THINK it will be clear. Will have to wait and see. Plus I shoot flames! Link to comment Share on other sites More sharing options...
vbrad511 Posted March 20, 2010 Report Share Posted March 20, 2010 It's not a clearance issue, it's a combination weight/movement issue. The soft aluminum of the head wn't take the movement of the motor tied to the exhaust and it's stability/weight. You'll develop exhaust leaks at the manifold and soon realize you the studs won't tighten anymore because the threads have been pulled out. Link to comment Share on other sites More sharing options...
Laodicea Posted March 21, 2010 Report Share Posted March 21, 2010 (edited) Here is some exhaust welds for ya I did. Turn the heat to 65 amps and you won't even need filler rod. http://i156.photobucket.com/albums/t18/gr8white1/2JZ%20Project/DSC01231.jpg Edited March 21, 2010 by Laodicea Link to comment Share on other sites More sharing options...
Drwojo Posted March 21, 2010 Author Report Share Posted March 21, 2010 /\ Not bad/\ I just have a 1-10 dial and wire speed. Either way I am excited for it. I just weld body panels normally. Link to comment Share on other sites More sharing options...
pure_insanity Posted April 4, 2010 Report Share Posted April 4, 2010 not bad work, and im glad to see you do it yourself and save all that money. as for the welding, my certification instructer told us that your not really a badarse welder untill, you can weld a straight bead and make it read f u c k y o u in the half moons. so far he said he hasnt seen anyone that could do it. Link to comment Share on other sites More sharing options...
Komeuppance Posted April 4, 2010 Report Share Posted April 4, 2010 Lawls. Even though the idea sounds funny, I'd say you did a pretty damn good job for your first time. What'd you use for that flange?? -Robert Link to comment Share on other sites More sharing options...
scott87star Posted April 4, 2010 Report Share Posted April 4, 2010 I did exactly the same thing to my 1984 Maserati Quattroporte with dual exhaust and four cats (two each side). For pretty much the same reasons too, bad bends restricting flow and I thought it would be much easier adjusting the fit with welded segments than bends. Worked great, sounded great. Nice job! Scott Link to comment Share on other sites More sharing options...
Drwojo Posted April 5, 2010 Author Report Share Posted April 5, 2010 Picked up a flex pipe for 7 bucks. Gonna swap it in today. Just got off work and get to waste money on skates and the car. Link to comment Share on other sites More sharing options...
Drwojo Posted April 19, 2010 Author Report Share Posted April 19, 2010 So I never posted pics of my flex pipe. Here ya go. Again crappy welds. It was difficult to weld thin metal to the exhaust pipe. Used JB weld to make sure all the pinholes are filled. I'm sure someone will pipe in and tell me that was a bad idea. I will post a vid as soon as I get a thread repair kit fix the stud on the turbo. Also need to weld in the bung for the Innovate and calibrate it. My mind is distracted with body work and bumper shaving! http://i160.photobucket.com/albums/t168/food28/0418002322.jpg Link to comment Share on other sites More sharing options...
Drwojo Posted May 6, 2010 Author Report Share Posted May 6, 2010 I finally installed the o2 bung and wrapped it. Was gonna install the wideband and calibrate it but the battery was completely dead. Wanted to make a short vid. Here is how she is looking. http://i160.photobucket.com/albums/t168/food28/0506000219.jpg Link to comment Share on other sites More sharing options...
Drwojo Posted May 6, 2010 Author Report Share Posted May 6, 2010 Wow that pic kinda sucks. I only seem to use my phone now. http://i160.photobucket.com/albums/t168/food28/0505001536.jpg Link to comment Share on other sites More sharing options...
dmyers151 Posted May 6, 2010 Report Share Posted May 6, 2010 Oh man dude, I'm gonna have an identical setup on my car this weekend, except with 3" tubing. With such a short section, I can't imagine you'll be needing that flex section, but we'll see I guess. Link to comment Share on other sites More sharing options...
Dave-O Posted May 7, 2010 Report Share Posted May 7, 2010 Not bad at all. Pie-cuts FTW. Link to comment Share on other sites More sharing options...
randyshaw81 Posted May 8, 2010 Report Share Posted May 8, 2010 (edited) Oh man dude, I'm gonna have an identical setup on my car this weekend, except with 3" tubing. With such a short section, I can't imagine you'll be needing that flex section, but we'll see I guess. Better to to have it and not need it, then to need it and not have it. Edited May 8, 2010 by randyshaw81 Link to comment Share on other sites More sharing options...
Drwojo Posted May 19, 2010 Author Report Share Posted May 19, 2010 Finally got a video. Sounds a lot like the old one or any other open dp starquest. 1. I warmed up the car before I made this video. 2. I know it is hanging low, I still need to weld on the hanger plus there is no fender on the car. 3. It is dirty and has dust and beer on it. http://www.youtube.com/watch?v=tCLkGySEAb8 Link to comment Share on other sites More sharing options...
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