How to Build Custom Exhaust?

[neuralracing]

I just bought this muffler:

http://www.meganracing.com/products/product_detail.asp?prodid=60

How many Mandrel bent elbows do I need to buy? I plan on buying either an EVO III O2 housing or a tubular one with atm dump.

What else do I need to buy? My local muffler shop will do all the piping for $160. I am getting rid of the Cat...

Does that sound about right?

 

[Boostd20psi]

just sell that tip and buy a turbo-back exhaust. But, if you MUST use that tip then have it professionally done. Thats the only true way to have things done unless you have a mandrel bender sitting in your garage or have access too.

Kenny

 

[NOSNUSE]

http://www.roadraceengineering.com/eclipsetech/1gawddiyexhaustpics.htm
Try here.

 

[neuralracing]

just sell that tip and buy a turbo-back exhaust. But, if you MUST use that tip then have it professionally done. Thats the only true way to have things done unless you have a mandrel bender sitting in your garage or have access too.

Kenny

I thought about that... but the cheapest Turboback I could find was the RnR which would run me about $800 with shipping to San Juan. cOnsidering I buy the O2 housing and a couple of Mandrel Bends... I will be at about half that price installed.

Why do you say I am better off selling that Muffler?

 

[Blurred Talon]

IF you have access to a welder then kteller.com for an exhaust piping kit.
Then just weld it together.

 

[miteclgst]

You don't need to have access to a mandrel bender in order to build your own exhaust. You don't need to get a different muffler either, I have a megan racing muffler also and couldn't be happier, people on this forum think that it needs to be thermal, apex'i or greddy to be any good, that couldn't be furthur from the truth. I did as most people do and bought a couple 180* 3" mandrel bends and then cut them to the angles i needed, tacked them into place and welded it all togeither off of the car. Here is a thread where I posted my project and all the specifics I needed. http://www.dsmtuners.com/forums/showthread.php?t=123985 granted you're an AWD and I'm FWD and that means that you will need less bends but the idea is still somewhat the same. I would strongly suggest getting all of your bends from www.magnumforce.com they are by far the cheapest mandrel bends you can find and they are top quality. If you are removing the cat I would also recommend 1 resonator, just to calm it down a bit because otherwise it will probably be unbearably loud. All of the other materials will be the same and all of the places I bought mine from were had the best prices. Good luck with your project, my only caution would be that if you have the muffler shop do any of the bending they will not be mandrel bends, they aren't a "crush" type bend but the do narrow out in the middle of the bend. For all of the work that is probably a pretty good price, I would be very specific where you want the tip to end up because my friend simply got a muffler installed and the shop charged him a whole lotta money and the muffler looked ridiculous. If you have any questions feel free to PM me.

 

[EclipseTrbo420A]

I didnt read what everyone else wrote but......just buy like 4 bends from JC Whitney and then have an exhaust shop cut/weld the rest intoplace .. im sure they willhave some straight 3 inch sitting around

 

[neuralracing]

What O2 housing should I buy?

 

[miteclgst]

The only real way that your 02 housing will effect the rest of your exhaust, build wise, is if you decide to go with the Evo 02 housing. The flange on the 02 housing is slightly more angled and this will need to be taken into account when you build your exhaust. your best bet is to simply have all of your parts before hand and that will make the build a lot easier. If you can't afford the 02 housing right now then simply port the stock one or use the stock simply as a reference, 90% of the tubular housings out there are made to bolt right on which means that as long as you get one compatable with your turbo you should have no problem.
There are a couple housing that are made one of two ways, they are either cast; 1g stock, 2g stock, and Evo - or they are tubular which accounts for atmospheric dump, or recirculated. And then there is the final option of the 02 eliminator that was mentioned before. Many people put down good numbers with the stock 2g housing ported, but you can do whatever floats your boat. I'm currently making a tubular 02 housing w/ atmospheric dump for my car with the DIY parts on RRE's website. But if you design your exhaust for an Evo housing than more than likely if you ever get tired of it you will have to fabricate your own tubular housing because any of the ones sold online will be made for the stock setup. If you build it with the stock dp then you can switch that with any tubular or cast housing that is made for your turbo.

 

[neuralracing]

I definetly want to go either with a Tubular with an ext dump or with the Evo III... which of the two do you guys recommed?

 

[nined2tsi]

Well given what all miteclgst just said prolly the o2 dump. Thats personally what I am going to buy just because of more flow. I could really care less about the sound.