Axleback+muffler customization/fabrication questions

[kenamond]

My 3" turboback should arrive via FedEx today, and I want to replace the single-tip, round, straight-through muffler with a Magnaflow twin-tip and some 3.5" slant cut rolled-lip tips. I don't plan on going past 350hp anytime soon, so I'm not too concerned about adding some minor bends to get the tips located as perfectly as possible relative to the rear bumper cover (centered, firing straight-back, and closer to the cover (higher) than stock). I'm a perfectionist, so I want to do as much of the mods as possible myself (if you want something done right...), but I won't be able to weld it myself, so I have a few ideas and would like input from those of you with experience and/or knowledge that relates to this.

This is the eBay juicyjems G-Power 3" SS AWD turboback (2.5" from O2 to flex outlet, 3" thereafter). I've been told that the exhaust fires straight back, but I saw atleast one image that looked a bit angled back to the driver's side. Also, it looked like the exhaust came out a bit lower than I'd like. I want to nestle the twin tips as close to the bumper cover as possible, filling that gap that the stock setup has by quite a bit. Also, I'm not yet sure how long the shipped setup's muffler is, so I don't know exactly how much space I'll have front-back with the Magnaflow (HxWxL=5x8x14, 3" centered inlet, dual 2.5" outlet with 4" outlet center spacing). The bottom line is that I'll have to cut and paste, so to speak, to get the tips where I want them.

First question: How close can I get the tips to the bumper cover without a heat issue (discolor/blister paint, melt plastic)? The tips will stick out just as much as the bumper cover (If you look straight down, the tips will be flush with the fattest part of the cover...give or take half an inch or so), and the passenger-side tip will stick out farther than the other, just like stock so that the tips follow the bird's-eye profile of the cover. I'd prefer double-wall tips similar to the stock tips (makes the tip walls look thicker), so maybe that'd help with heat a bit more than a single wall tip.

Second question: Can I use clamps and exhaust couplers to hold the thing together while I'm cutting and pasting and maybe use wire to hold the thing up in lieu of welded hangers? I sure as hell don't want to lose $300 worth of muffler/exhaust/tips on the road driving 45 minutes to a muffler shop, but I'd like to be able to deliver it and say, "weld it so that it looks just like that".

Third question: Can I do all of the cutting with a hack saw, Dremel, die grinder and tin snips/shears? I don't have a band saw or other, more suitable metal cutting tools. If there is a cheap-ish tool that I shold buy, let me know; more tools is always a good thing.

Fourth questions : Would I be able to fabricate the hangers with a vice, hammer (rubber, plastic, metal, and/or sledge) and the above cutting tools? I've never shopped for hanger material; where do I get it? I have a decent set of tools. The toughest hanger might be the one on the back of the muffler; the stock hanger has a bracket welded to the back face of the muffler.

Fifth and final question: I've never done this before. Is this plan loco?

Sorry for the long post. Thanks for the help!

EDIT: I probably should've posted this in a different forum. Moderators feel free to move it.

 

[blcknspo0ln]

Just found this guy:

Part Number VIB-1149

 

[kenamond]

I got the Magnaflow 12198 sitting in the garage. Tips are supposed to arrive tomorrow. Never heard back from the welder, but a guy I work with simulates metal cutting processes (lathes, mills, etc.) and works with several machinists that he said could probably do the welding. Need to get him to give me names.

I drew up and cut out what the tips will look like with the correct diameter and spacing of the dual outlets and held it up behind the car. Might be a bit tight fitting them in that nook without it being too close, but it still might fit very nicely. Hope I don't burn the paint off of the bumper cover or melt it .

Did a pull a few days ago at 12psi. Rose to 14psi at redline . With stock exhaust and 15psi, it would drop to 10psi by redline, so this is good. However, I still see 3 degrees pulled at higher rpm. I had that problem with stock exhaust even at 9psi. O2v this last pull were 0.96v and dropped to 0.94v in the top third of the pull. Airflow at redline was about 22lb/min loads were between 1.5 and 1.7g/rev. No clue why I have this knock. But that's a different story.

 

[kawboy]

Can we get a pic of the exhaust installed from the back of the car?

Does it tuck to the bumper? Sit at any angle? Thanks

 

[kenamond]

Can we get a pic of the exhaust installed from the back of the car?

Does it tuck to the bumper? Sit at any angle? Thanks

It looks exactly like post #29 (blckspoOln's images). It's not tucked in there very tight, but that might look bad if it did, because it's a big honkin' single tip. I'll certainly post pics when I get the twin-tip Magnaflow installed, but that'll probably be a week or two (searching for a good SS welder who won't charge an arm and a leg).

 

[kawboy]

That sits pretty nice

Is there a way to adjust it to sit at an angle or higher/lower?

I got a 3" catback from nissangtrpower "SR*S" and it sits like this:

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A bit on the low side, it's also VERY quiet. It has got somewhat louder since new, but you can't even hear the exhaust when cruising, and even when boosting it certainly doesn't scream like my Thermal did on my Talon.

 

[kenamond]

There isn't an easy way to adjust the angle of the muffler without cutting and welding. The muffler does slope up, though. To change it, you'd have to cut the muffler off and reweld it at a different angle and also modify the rear hanger on the back end of the muffler. But this thing is LOUD.

 

[kawboy]

How do you think I'd be able to make my SR*S sit higher? Bending the hangers down? It just looks so goofy with that gap, should sit more flush like yours

 

[romeen]

How do you think I'd be able to make my SR*S sit higher? Bending the hangers down? It just looks so goofy with that gap, should sit more flush like yours

What about using a shorter rubber hanger or even an adustable one like this.

Dynomax Performance 35945 - Dynomax Exhaust Hangers - summitracing.com

I haven't looked at our exhaust hangers in awhile so I am not sure if it will be compatible or not.

Interestingly, I got my exhaust from a different ebay vendor than you (japanimportshop) but mine is also made by SR*S. I haven't installed it yet so I'm not sure how it will sit but I agree with you that I don't like that large of a gap between the muffler and fascia either.

 

[blcknspo0ln]

Well, just to clarify (yes I spoke to juicyjems, the vendor) it is an XSPower exhaust, shipped directly from their factory. The ebay vendors are just middle-men.

As for the XS one, it sits really high and really firm in the bumper opening ; providing you use all of the hangars and bolts (especially the lost one).

 

[romeen]

=kenamond;151443478]It looks exactly like post #29 (blckspoOln's images). It's not tucked in there very tight, but that might look bad if it did, because it's a big honkin' single tip. I'll certainly post pics when I get the twin-tip Magnaflow installed, but that'll probably be a week or two (searching for a good SS welder who won't charge an arm and a leg).

I wonder why it's so expensive to weld SS. I was quoted $50-60 just to cut off the neck down portion where it connects to the cat and weld on a 3" section to match the rest of the system. It seems like it would be easy but then again I don't weld.

 

[kawboy]

Well I tried mounting it higher (Looks great by the way, angled out + flush) and it hits part of the frame where it's crimped.

I think I'm just going to take it to a local Meineke and have them cut/bend/weld do whatever so it looks normal.

 

[romeen]

How did you make it sit higher?

Do you think heat wrapping it would be enough to dampen out or quiet the impact/vibration against the frame?

PS- Sorry Mack, not trying to hijack your thread.

 

[blcknspo0ln]

Just remove the exhaust and take a hammer to the hangers?

 

[kawboy]

I put the fart can on a jack and disconnected it from the hangers.

If I had a car lift I'd be able to do this s hit but it sucks working on a sloped driveway on my back.

And bending the hangers wont work. They need to be cut and shortened, possibly relocated.

 

[kenamond]

Got the tips the other day. DAMN THEY'RE HUGE. I think I'll have to cut them down to size. The perfectionist in me is bumming hard, becuase "AERO" with "TURBINE" below it is pressed into the SS on both sides of each tip. I'd have to cut them about in half, so I'd have "AE" and "TURE" on one side and "RO" and "3INE" on the other (note, "E" is half of a "B" and "3" is the other half of the "B").

I'll post pics of the tips giving some size perspective. Time to color Easter eggs with the kiddos (parenthood...).

Still haven't found a SS welder, but that just gives me more reason to stall and think and fume.

Oh, and the faucet/spigot on the side of our house popped over the winter. Leaks water into the wall when you turn it on. Found that out after the kids had the hose on for lord-knows-how-long. Basement ceiling was leaking water from the canister lights, ceiling sheetrock seams started sagging, main-floor living room carpet is wet, and living room wall sheetrock is bulging at the floor. When it rains...

 

[kenamond]

Took some pics of the tips and muffler. Also included one of the existing can muffler.

So you can see that the can muffler comes pretty far back on the car, so I don't have much room for the new tips. The Magnaflow muffler is 1" shorter, but that doesn't buy me much room. I don't want the tips sticking out 5" past the rear cover.

Next shows the tips "on" the Magnaflow. Too long.

Next shows the tips shifted to around where I'd need them. Need to cut the tips. Note that the tips are like a sock pulled off your foot half-way inside-out. It's one piece of SS that wraps back on itself.

Finally, I include an image of one tip with my hand for size perspective. Very nice tip. Too bad I have to cut it in half. Oh, and my hands aren't small, either. The tips are HUGE.

 

[kenamond]

Well, all of the welding is done except for a small tab for the rear muffler hanger. Lot of work, but I learned a lot, got some new tools and met a great welder. The hanger gets welded tomorrow morning, then I'll sand and paint all but the tips with a few coats of flat black BBQ paint. Turned out AWESOME. I'm a complete pro at removing/installing the axleback now. And it only took me...18 hours (so far) Well worth it, though.

I'll post final pics maybe tomorrow.

 

[Mr Peepers]

Looking forward to it!

 

[kenamond]

Pictures. I have several dozen, but these should do.

The Magnaflow 12198 fits the 2g bumper perfectly IMO:

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Painted and ready to install:

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The rear hanger turned out to be about as simple as you can get...all luck! A wrench fits right up between the tip and muffler body and a socket fits the bolt head without hitting anything, and a simple tab of 1"x1/8" steel strap with a hole is all it took:

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I need more pictures of it on the car, but the car is dirty and dented But here's one.

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I love it. "In the spirit of stock"

 

[blcknspo0ln]

I'm so friggin jealous right now. I think the black sleeper paint REALLY adds a lot to the system. I've grown accustomed to my exhaust and I think the stealthiness is awesome.

Mack, did it get quieter? Since I'm ok with the looks now (I kinda like it the only reason I'd consider switching is if it got significantly less audible.

 

[kenamond]

I'm so friggin jealous right now. I think the black sleeper paint REALLY adds a lot to the system. I've grown accustomed to my exhaust and I think the stealthiness is awesome.

Mack, did it get quieter? Since I'm ok with the looks now (I kinda like it the only reason I'd consider switching is if it got significantly less audible.

It's quieter, but not by a huge amount. An unexpected thing happened though...because the tips are different lengths, there are actually two "notes" to the exhaust that are close, but you can hear each. I just drove 680 miles round trip to pick up a bumper cover. Put the boost back at 14psi before I left and washed the car. Man I love my car! Tromping it at 4k is an instant kick in the pants...it spools up almost immediately.

If the drone of the exhaust bugs me over time, I'll put in a high-flow cat. I no longer fear metal working so I can cut up the DP...maybe even put in a true 3" DP...or maybe make a 3" O2 housing. And I now have a great welding contact.

I'm gonna start sanding the new bumper cover I got and try straightening out the metal bracket that runs along the bottom. Any idea if anyone sells those brackets or if it's the same as an eclipse bracket? Mine got mangled and I bashed it pretty much back into shape, and the new one has some twistiness to it, too. Wonder if the Avenger/Sebring has the same bracket...hmmm...time to Google.

 

[JaxonsGSX]

I've been thinking about doing this for awhile now. Im just not a big fan of the ''fart can'' look. Plus mine's a little to loud for me also, and seeing how well yours turned out im going to do it! Great job man! Think we could get a sound clip??

 

[98GSXtreme07]

I love the way the exhaust ended up coming out! Glad that you like how all your hard work, time, and money came out. It looks amazing! You wouldn't have any clips of how the exhaust sounds would you?

 

[kenamond]

I've been thinking about doing this for awhile now. Im just not a big fan of the ''fart can'' look. Plus mine's a little to loud for me also, and seeing how well yours turned out im going to do it! Great job man! Think we could get a sound clip??

Thanks! The mix of the can look and the can sound bugged me tooooo much. At least one of those is fixed now. It's not quiet, but it's quieter.

I have no idea how to get a sound clip. I have a nice cell phone that can probably do it, but it has maaaany features I've not yet figured out...used the calculator function today though...31.8mpg on my trip to Denver this morning. Anyway, what is the common way of getting a sound clip and where do I post it? Maybe I just take a movie and post it on utube? ...I'm a noob at that stuff but I'm ironically also an old fart.

 

[JaxonsGSX]

I know what you mean about the sound and look buggin you BELIEVE me . I mean im tryin to build this car right, and keep it clean, and all people do is look at that big ole ricer fart can. Never mind all the hard work. But yea putting a vid on youtube would be easy, then just give us a link. It would be much appreciated! I was looking at getting a magnaflow befor i found your thread so that'd be great!