Custom Exhaust Questions

[orangedsm]

Ok, with me being stationed over here in Italy, where the only people who know what a 4G63 or AWD DSM are the very few American DSM fans on base, I am not going to be able to find an exhaust system here. Since shipping isn't an option either, even a catback system is too big to ship to an APO overseas address :thumbdown I have decided to order a downpipe and then custom make the rest of it.

I've got access to a lift and a welder for cheap ($5/hr) so I was gonna order some mandrel bent piping and some straight sections and just cut and weld. They don't care if we have a cat here, there is no emissions testing for Americans here, so no big deal. Then I'm gonna order the muffler of my choice (probably N1 or something similar).

So has anyone done this before? I'll have access to all the right tools, so it won't be bad at all. Mainly I'm just wondering if anyone has done this, what all kinds of piping did you order? Where did you order it from (JCWhitney any good?) and how much did it end up costing you? I'd like to get Stainless steel for longevity, I plan on keeping this car a long time.

Also, where can I purchase REAL name brand mufflers, all the crap I see on ebay is N1 "style" and HKS "style" I never can find the real things.

So any help or any kind of suggestions would be appreciated. Thanks!

Jason

 

[goonie]

i did the same thing my self i ordered the pipes and bends from bosal
they have all kinds of pipes i made mine from 3inch tube(not stainless)from turbo to the muffler.
you are stationed in europe just like me,just find a car shop that sels bosal exhaust
the will have a catalogue with all the pipes and bends you need or check www.bosal.com
the system works great i also made the muffler my self tough just n open muffler like the cheap ones on ebay it gives a deep sound and i also had an increase in turbo boost
my boost went up from 0.9 to 1.1 the whole exhaust costed me arround 125 euro
tip; if you make your own downpipe make sure you use a flex,and just follow the route of youre stock exhaust .
good luck

 

[orangedsm]

Thanks for the response, I appreciate it. Too bad yours is FWD, that means our exhaust routing is different, or else I'd ask you what bends you used. Oh well, thanks for the info!

 

[jb95gst]

I took mine to a local shop and they bent the tubing(press not mandrel ) but mine is mostly straight, then there are two bends right near the end before the muffler. Maybe like 20-30* total, mine is just a catback and is on my 95 awd. Hope this helps,
JB

 

[goonie]

Thanks for the response, I appreciate it. Too bad yours is FWD, that means our exhaust routing is different, or else I'd ask you what bends you used. Oh well, thanks for the info!

hmm too bad but try this link www.fvaq.com go to the exhaust section there is a nice article by tom stangle about a 3inch exhaust systym for an AWD with pictures
hope it helps anyway good luck

 

[goonie]

Thanks for the response, I appreciate it. Too bad yours is FWD, that means our exhaust routing is different, or else I'd ask you what bends you used. Oh well, thanks for the info!

oops i think thats the wrong link try this one it must take you straight to the right page
www.fvaq.com/mods/exhaust2.html good luck

 

[goonie]

Thanks for the response, I appreciate it. Too bad yours is FWD, that means our exhaust routing is different, or else I'd ask you what bends you used. Oh well, thanks for the info!

well i messed up again it suppose to be vfaq not fvaq sorry for the mess up
but this should be right www.vfaq.com/mods/exhaust2.html

 

[homeless]

a buddy and i built my exhaust 3 inch mandrel from the trubo and dumps behind the doors. i slid a flex section and 24" long glasspack in to take care of noise. i spent $150 when you add the cost of the paint.

actually my buddy who helped me worked at ELSA from 94-98 and used to build the stock exhausts for dsm's

 

[yoshimitsuspeed]

This is for a 95 gsx so I think it's a different routing.
I got a bunch of 3" flanges and matching gaskets. 2 90 deg bends and one 45 and a ten foot section of 3" pipe. I would think you could find a muffler shop over there that has 3" pipe. Of course I don't know where you are located or how populated it is there, plus they might look at you like you are mad since none of the 1 liter euro cars would need a 3" ex.
I cut the stock flanges off my o2 housing and welded a 3" flange on then I ported and polished the housing as much as possible and flared the end out to three inches. I didn't like the thought of it going straight from two inches to three. I figured the flare would create a smoother transition. I am running the t25 at stock boost, I have no signs of boost creep. Next I bolted the next flange in place, tacked the 90 in tacked the straight pipe to the flex pipe, added another flange there and one more wher my apex i bolts on the end. Next I took it off and welded it all up. Other than porting and welding to the cast 02 housing it was pretty easy.