Aluminum exhaust from scrap sheet aluminum?

[RipperXX]

Once this is finished, I'm sure a lot of people will want to hear what this sounds like.

I'll make and post a recording, with the car in and out of the shop..maybe in car, outside too.

Here's the current fitment.

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could be better, but it will do for now, at this point I just kind of want it done. sucks not having a TIG welder in my shop...I'm going to look for an air cooled unit after this coming tax return.

 

[petegsx]

I'm interested in the sound! You will have to post a video when you put it on so we can hear it. Keep up the good work

 

[RipperXX]

Well I packed the muffler tonight and slid the rear cap on, so all that's left on the muffler is to weld that end cap on and it's done. I think it's going to be a awesome muffler too! I used two packages of Bondo brand fiberglass mat, just put on some rubber gloves and tore chunks from the sheet, somewhat wadded it up and packed it. slid the end cap on, raised it took a breath and started a steady loud yell and moved it to my mouth. its like yelling into a pillow! I can't hardly believe it, works so well being straight through.

I can't wait, I made another bend too, getting real close now.

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[scotthidley]

You need to anodize it some obnoxious color just for the fun of it.

 

[2G-BlackGst]

^^^ I am one of those people.. haha When I read the first post I was reallllyy skeptical but seeing the pics... props man, will be following this. Please post a vid when its done!!

 

[yoscoobie]

Well I packed the muffler tonight and slid the rear cap on, so all that's left on the muffler is to weld that end cap on and it's done. I think it's going to be a awesome muffler too! I used two packages of Bondo brand fiberglass mat, just put on some rubber gloves and tore chunks from the sheet, somewhat wadded it up and packed it. slid the end cap on, raised it took a breath and started a steady loud yell and moved it to my mouth. its like yelling into a pillow! I can't hardly believe it, works so well being straight through.

I can't wait, I made another bend too, getting real close now.

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for the packing you can use the exhaust packing sold from the motocross bike store, it works very well and comes in different forms, i like the roll just wrap it tight and safety wire it on so it stays really tight

 

[RipperXX]

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Closing her up.



Brought to you by, scrap

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[RipperXX]

Finished with muffler...well it needs hangers but that's it.

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Probably 10lb. for the SS muffler...

 

[boostdawd]

Looking really good! The more I see threads like this the more I want to buy a welder. Great job!

 

[RipperXX]

Layed out, I appear to just need hangers, that one piece that's missing, and to adjust the 2nd half of the long straight piece a bit...and cut some out of it where ti drops down, it drops down to much. Going to cut half of that transition piece out of it and angel it down a bit (it's currently slightly up a degree or two)...and to the drivers side some as it's a degree or two towards the center of the car to much and the end is right next to the rear diff. Then just tack, verify, weld and WALA BABY!!!

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Well, I'll make a "tip" too... same diameter as the pipe but polished and angel cut on it for aesthetics.

 

[RipperXX]

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So close.

 

[Vegas Smith]

And this is all for that lawnmower on the right???

 

[Geeb]

That's so awesome. I remember learning to you aluminum in school. Talk about a low temp melting metal haha. Awesome work man.

 

[RipperXX]

Small update, tomorrow I should have the two pieces joined. Hopefully I marked everything well enough it all lines up on the first try

Here it is, as is.

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Once the two are one... it's just weld a piece to the exhaust that will slip over the mufflers connection and clamp, and tweak a few hangers and I'll be recording what it sounds like! So excited!! Never done anything like this, the whole thing made from scrap minus the fiberglass, by me! it's very rewarding.

 

[RipperXX]

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Now I just need to make the piece to attach the muffler.

 

[Airsign89]

Nice work, man! Any chance you could weigh it and the factory exhaust to see how much you saved?

Btw, I love the FD wheels on your car.

 

[RipperXX]

Nice work, man! Any chance you could weigh it and the factory exhaust to see how much you saved?

Btw, I love the FD wheels on your car.

Unfortunately I don't even have so much as a bathroom scale. But I'll stop somewhere to see about getting one, because I'm curious as well.

Welded on the piece that is supposed to slip over the inlet to the muffler. I think I may have to fight it some, but I hope not to much. Still need more hangers so it is ready to go for a drive,me yet even if I get it on. But I'll crank it and rev it up some to see what it sounds like.

 

[RipperXX]

Well, it's on, and running...that's the good news. Bad news is I have to take it right back off as the connection I made had to small of an I.Don't. But...being dedicated to giving you few interested parties a taste. I made some cuts, opened it up and pounced it on . I'll be taking it back tomorrow to come up with a serious attachment. I'll post the video in a moment..cars still warming up and ideling down.

 

[RipperXX]

Ok, how the hell do I upload the video from my phone.

 

[Airsign89]

You could put it on YouTube and then do a direct link, as one option.

 

[RipperXX]

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So like I said earlier, the connection is about as ghetto as it could possibly be. But I wanted to get an idea of what it would sound like. I don't think you can hear it in the video but there was a sort of funny chirping sound at idle from the 2 bolt flange leaking because I didn't bother to put a gasket on since I was going to turn around and pull it right back off. Still need hangers, it only has 1 right now. Which is why the jack stands are there to support it.

I'll post pictures of the weight difference in moment. Hopefully I will have it connected for real, tomorrow.

 

[RipperXX]

So here is the whole 1g catback...minus the cat, in it's place was a test pipe.

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Zoom in if you wish, but it's 30lb. (bought this scale just for this btw guys.)

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So how much did the aluminum weigh? Keep in mind, it's all 1/8" aluminum, but the muffler is stainless steel.

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Exactly HALF...15lb baby! that's with the stainless steel muffler btw.

 

[RipperXX]

Connection piece remade, muffler slides in like it should. Now I just need to get a clamp on the way home....also put a short anglet cut tip on the muffler. Hoping it just sticks out a bit as I don't want black on my bumper.

 

[Kapok6]

Awesome.

 

[RipperXX]

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