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.

 

[kenamond]

Installed pictures. Ignore the damage to the rear-passenger corner and dent in the cover.

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[blcknspo0ln]

That is so freakin' hot. I need to get on this ASAP. Well, as soon as my shitbox is fixed.

 

[914g63gsx]

hey man mad props. now i am thinking about doing it hahaha. looks real good, any way to get a sound clip? oh and were did you get the tips i wanna do this so bad i found the muffler from the part number you letf.

 

[blcknspo0ln]

btw, it looks like you have at least a digital camera. One of the settings should allow you to record a video If you have the video, just upload onto here.

 

[kenamond]

I'll get a sound clip eventually. I've never recorded a movie on my cell, and I've never uploaded anything to youtube. I also have many things on my Talon to-do list.

I promised Mr Peepers some pictures of the mockup I made. I don't think it was essential, but it really helped me in the beginning before I made the first cuts and with the next couple of major cuts. After I made it, I proudly held it up...then held the read one up...then the mockup...while doing to which my wife did

I'll just post the links...enough inline pictures as it is.

Here's the mockup of the Magnaflow. Posterboard and scotch tape.

Here are the tips with the mock muffler in place checking clearances and angles.

From underneath.

This shows how I decided how to do the first "close" cut on the axleback pipe. I wanted the muffler as far forward as possible, but I had to leave enough room to weld between the muffler body and those hangers.

Here's a picture of that weld. I gave him "just enough" room. It was a bit tight and the weld was a bit wobbly under that hanger, but whatever...it works!

 

[98GSXtreme07]

Wow! That's definitely some nice paper skills you got there!

 

[Mr Peepers]

I would honestly think that's stock if I didn't look at it twice. Looks AMAZING; I'm really liking the black muffler. Was that just BBQ paint? EDIT: brand? Seems a little more lively than the Rustoleum stuff.

That is so freakin' hot. I need to get on this ASAP. Well, as soon as my shitbox is fixed.

Yeah, what a pos

 

[kenamond]

I would honestly think that's stock if I didn't look at it twice. Looks AMAZING; I'm really liking the black muffler. Was that just BBQ paint? EDIT: brand? Seems a little more lively than the Rustoleum stuff.



Yeah, what a pos

I'm pretty sure it was Krylon special purpose BBQ paint (I'll look at the can when I get a chance). I took 220grit aluminum oxide sand paper to everything but the tips. The welder guy took a wire brush to the back of the muffler and welds on the muffler/tip joints). Then I wiped it down with acetone. Then masked off the tips and did a couple coats of BBQ. The welder guy said he thought the BBQ paint had to cure at high temperature, but I figure my 680 mile round trip to pick up a front bumper cover near Denver on Saturday probably did the trick if curing is in fact necessary/recommended.

It's definitely quieter. Atleast it doesn't set off the car alarm in the parking garage at work.

The tips will get dirty/sooty as you drive it, but I cleaned it up with acetone and it was like new (maybe soap would work, too, but I just used acetone so far). They were kind of sooty after the Denver trip.

 

[Atuca]

Mack, great stuff man! and I thought my clutch install was an accomplishment, than you go and fabricate the most bad ass looking exhaust ever. I really want to hear it now!

 

[kenamond]

Well, it's been 5.5 years since I did this. Since then, my car got totaled in a hail storm, backed into by my neighbor (left a note, bless her soul), and backed into by a stranger (damn his/her soul). Then my now-ex-wife spent the insurance money ($6700) on...dunno. But the exhaust is still great!! A bit too loud, but I got used to it (and I have a loud stereo).

The one change I'd make is to add a 2nd muffler where the cat used to be. Single 3" inlet, single 3" outlet. Some day, I'll do it. When I do, I'll tag it on the end of this thread and have the longest *meaningful* DSMTuners thread ever!

So my car looks very slow now (golf-ball-esque, dented door, fender, and scuffed-up bumper cover), passenger door strake is off (started coming loose, and, since they're a bi*** to find, I yanked them until I get the hail damage on the door fixed and the car painted...didn't want it falling off on the interstate and loosing it!!).

But, she runs great! Love my DSM. Ordered it new from the factory in October, 1996 as my first new car. Will never sell it. Hope to give it to my son some day...in tip-top shape, both inside and out! But only if he helps me work on it Maybe he'll be a wiseman some day.