Updated design:
Progress on building the new exhaust. The welds a’it purdy but they’re solid and not too bad considering I’ve never used a TIG before and have learned how to use it with YouTube tutorials…
Step 1: Remove the old exhaust:
Step 2: Test fit some pipes, ordered the wrong bend, so either need to modify or get another one
Step 3: CAD (Card board aided design) to get the angles for the 2″ to 2.5″ transition. The height difference is 80mm, the input and output are parallel.
Step 4: Transition parts tacked together with v-bands clamps at one end. The v-band connects the backbox to the rest of the pipes, will allow for some angle adjustment later if needed.
Step 5: Back gas feed, v band clamp in place to reduce chance of warping when welding that part.
Step 6: The two height / size transitions welded up (don’t look too closely). Back gas worked well, clean weld through no sugaring / oxidisation on the backs.
Step 7: Cut down the inputs on the back boxes, they input at a slight angle so needed cutting flush for the v-band to be welded on.
Step 8: V-bands welded on – these were both back gassed
Step 9: Cut out hangers for from stainless tock and cut holes in each.
Step 10: Hangers bent 90º – welded these on, bit of a tough one to get the amps right, melted away a bit much of the original metal but I think I made it longer than it needs to be to compensate.
Step 11: Finishing up welding the first piece – this goes from the exsiting output all the way to the back box
Step 12: Pipe in place, it will be clamped were the colour changes from stainless, to stainless covered in dirt
Step 13: Back box in place on the hanger (into the existing E36 style exhaust hanger).
Step 14: May need to move the head shield a bit as the back boxes are closer to the centre of the car due to the offset inlet.
The bullet mufflers are now no longer part of the exhaust system, in theory the closed setting should be quieter than before and open should be the same or louder!
Step 14: Cut down the output pipes, otherwise the tips would stick out too far.
Step 15: Tip test fit, could move these back further by cutting the tip input down a little which would make the hole bigger.
Step 16: Test fit on car, it’s just push fit to at this point
Opened up the cover that’s over the mechanisum which actuates the volume flap
View from the top, position seems quite good here
