Lets talk Custom downpipes.

[twicks69]

Contact a local Semi-tractor repair company that does exhaust work. They should be able to get anything from 3" and larger (usually up to 7"). It will likely be cheaper than most other places.

I haven't seen a 3.5" flex section on the web anywhere; just 3" and 4". Here is a link to good priced flex sections:

Flex Bellows: atpturbo.com

 

[1fastlaser]

Contact a local Semi-tractor repair company that does exhaust work. They should be able to get anything from 3" and larger (usually up to 7"). It will likely be cheaper than most other places.

I haven't seen a 3.5" flex section on the web anywhere; just 3" and 4". Here is a link to good priced flex sections:

Flex Bellows: atpturbo.com

For reference

3.5" OD x 6.0" Long Stainless Flex Section

 

[twicks69]

For reference

3.5" OD x 6.0" Long Stainless Flex Section

Good find! Thanks!

 

[99gst_racer]

Look closely at Jakes radiator . Afco scirocco. It wouldnt fit if it wasnt there. You can also see the ic pipe if you look closely.

Why wouldn't it fit? (I'm assuming it's because the compressor cover needs to be clocked towards the radiator the front roll stop??)

If that's the case, then have you considered not running a front roll stop at all?

 

[toofast82]

http://www.dsmtuners.com/forums/newbie-forum/316211-shearer-3-5-v-band-exhaust-pics.html
Shearer Fab is working on a 3.5" full exhaust for 1g. He has built a prototype, check it out

 

[twicks69]

Why wouldn't it fit? (I'm assuming it's because the compressor cover needs to be clocked towards the radiator the front roll stop??)

If that's the case, then have you considered not running a front roll stop at all?

The front mount is pretty important. If you end up completely removing the stock one, I would suggest running a tubular front cross member like Jake did -- it was an awesome piece that just used 1 5/8" Chromoly, utilizing the rear mount location, and then making custom mounts on the front. He then also fabricated up traction bars from the cross member to the front lower control arms using hex swedge tube with heim joints. For the front motor mount, he used 1" swedge tube with heim joints to the front block mount tab; through-bolted to the tubular cross member.

Here are a couple pics for reference:
http://www.jhracing.net/images/Money_Engine.JPG
http://www.jhracing.net/images/Money_Engine_2_.JPG

The Scirocco radiator was a nice piece because it could fit up tightly to the radiator support bracketry with a couple of lower tabs welded in, and upper brackets fabricated. It allowed for the radiator fans to be fitted in the engine bay as a puller setup, and left alot of room for the intercooler piping to be installed and removed without troubles.

It was really a very nice setup with alot of time and thought put into it.

 

[64_Frankenstein]

So i have all my goods together to put on My ON-GREEN t4 cast manifold with a gt4294. Now ive been searching for mandrel piping. Its really expensive to get this done. I was looking into stainless but you have two different kinds 409 and 304 stainless. 409 is from the explaination what they use on factory exhaust systems for cars/trucks and ofcourse less expensive. 304 is typically what nice tubular manifolds like dnp etc, and way more expensive.

Talking to acouple friends that are fabricators i gained some information. I was told if money is tight, do a mild steel downpipe, have it ceramic coated. I was going to put another v-band to seperate the downpipe from the back part of the exhaust. The 2nd part of the exhaust is going to be aluminized. Found out i have to use a 309/312 mig wire, if i remember gas to be used is straight argon.

I planned on doing full 4" turboback, but now maybe for the sake of making it alittle easier i might do 3 1/2". I doubt ill see any or little loss, but if anyone thinks otherwise please let me know.

Now the question is for guys who fabricate exhaust, and maybe know were to go with things as ceramic coating, metal type please let me know. It comes down to this

If i was to do stainless would 409 be ok, and can it be coated? Or sould i just up for a 304 stainless downpipe (remember after the downpipe, there will be a v-band then aluminized steel the rest of the exhaust).

Or sould i just to a mild steel downpipe, get it ceramic coated (were is the best, i know jet hot, but other opinions count).

Talking about a mandrel pipe bender you're going to spend some serious money. Im just like you and always wanted one. Here some pictures of my exhaust down pipe I made for my T3/T4 turbo. It takes time to do this but its the cheapest way to do. All you need is a digital saw off cutter and a good MIG welder. I got these pipes from the muffler shop not really sure what kind of metal is it but it works great and holds alot of heat. I would go with stainless steel but cost alot more. I'll go with rap it insted of coated. The down pipe I'll say I'll go with 4 and the rest is 3.5. These pix is just a little idea and hope it helps.

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[ceedawg]

Some updated pictures

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the afco scirocco radiator will give me the room i need to angle the compressor outlet more forward.

How do you like that exh mani?

 

[1fastlaser]

I got all my mild steel piping in, 3 1/2 inch. Theres acually a place 3 minutes from my house that does ceramic coating so thats the route im going. Shearer makes a 3 1/2 turbo back gt42 exhaust for his top mount manifolds, so i dont think ill have any issues what so ever. Im going to be making the exhaust this weekend so ill have some updated pictures.

I love the manifold, im not a fan of tubular manifold because i want something that will last, i drive the car alot, and far on the weekends. I dont wont to worry about it cracking eventually and having to take it off and sending it out. Yeah it might last for years, but if it dosent i would probably smash the manifold and melt it into a lawn ornament.

 

[01QuadDak]

I relocated my alternator to the rear of the motor, ### my punishment racing 3" dp was cooking it.
Anyways, since i put a FP88 on it i had to redo the dp, and here is what i came up with-

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[99gst_racer]

^^^ Nice work.

I'm currently working on a pretty trick DP for my twin turbo set-up. I'll post some pictures as soon as I'm finished with it.

 

[1fastlaser]

I finally made my downpipe, dont mind some of the welds, as i have updated pictures when them cleaned up. It looks nice with the welds cleaned up. Keep in mind also this was the first downpipe ive ever made.

 

[99gst_racer]

Pictures of my final downpipe design. This is for my compound turbo set-up, so it's alot like a topmount-style downpipe.

The entire section seen in the first picture will be sent off to be jet-hot coated along with the compound turbo exhaust parts.

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[andy4g63]

This stuff is awesome, Paul. Only downside, you'll get a lot of heat in the engine bay. Hope it is worth the power gains, or spool time.

 

[1fastlaser]

Sweet man, nothing like doing it yourself. Heres my finished downpipe, cleaned up and ceramic coated.

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[99gst_racer]

This stuff is awesome, Paul. Only downside, you'll get a lot of heat in the engine bay. Hope it is worth the power gains, or spool time.

The internal and external Jet-Hot coating on everything should help out quite a bit. Not to mention I have a two hood vents directly above this assembly. I'll make it work well.


1fastlaser - Where did you have your downpipe coated?

 

[Scrymerr]

I finally made my downpipe, dont mind some of the welds, as i have updated pictures when them cleaned up. It looks nice with the welds cleaned up. Keep in mind also this was the first downpipe ive ever made.

Ribbed for her pleasure?

 

[Slippi84]

Ribbed for her pleasure?

Carver is more a function that looks guy especially under the hood . I still think it looks pretty dam badass all put together

 

[kicker91laser]

Looks really good guys. Paul, how much is Jet Hot charging to coat all of your parts?

 

[nfernotalon]

You guys made some bad ass downpipes, Im looking into this myself now that I have my Holset. I dont have access to a welder and cant weld for crap anyway. If anyone is interested in making me one for my Holset please pm me! thanks.

 

[99gst_racer]

Looks really good guys. Paul, how much is Jet Hot charging to coat all of your parts?

They sent me an info packet and a quote by mail. I believe it was around $570, including returm shipping. But I have a good feeling it's going to be a bit more once it's all said and done.

 

[TalonESIT]

This is the mandrel custom 3-inch downpipe I made back when I had my talon (complete with v-bands)...its ugly, but it was fun to make..(I only had a Mig welder though)..

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[1fastlaser]

The internal and external Jet-Hot coating on everything should help out quite a bit. Not to mention I have a two hood vents directly above this assembly. I'll make it work well.


1fastlaser - Where did you have your downpipe coated?

Its acually called johnsons powder coating in burlington NJ. It was close for me and he charged me 80 to coat inside and out. I think it looks great.

Yeah it looks alright, its the first downpipe ive ever made. I was trying to keep the degree of the bends as smooth as possible, which it came out awesome i think. Next one will get tig welded.

Just finished up the full exhaust this passed weekend, got one spot we gotta fix because it hangs alittle low, but no bigger. Sounds great also with the dynomax bullet 4 inch inlet outlet muffler. Ill get pics

 

[99gst_racer]

HA, funny you mention that. I was building a 3.5" turbo-back for a buddy's 2G this past weekend as well. I only got half-way done with it though. Going back tomorrow to finish it. His was tricky though, because the car has a solid axle 9" and a 4-link. It was tricky routing a 3.5" diameter pipe around the 4-link. It's pretty cool though. The whole things uses really lightweight 20 gauge SS piping, and one of these ultra-light 2-stage mufflers.

 

[kicker91laser]

Paul, please post pics of said downpipe and car.