Tips for building bumper, side exit exhaust?

[v8s_are_slow]

Getting this done in a couple of months on my 2g and would "like" to do as much of this as possible on my own (aside from the welding cause I don't have a welder). I'm running a big T-28 and will be using the stock type flange. This will have a muffler (my ATR if it'll fit, otherwise a racing muffler from extreme) just to keep it from being totally obnoxious. Want it to exit to about a 4" diameter out the side and would prefer to have the pipes to slip into each other for more strength versus welding end to end and the welds fail. Wondering the best method for using a hanger (and drill a hole in the bottom of the frame or what?) so that the weight doesn't kill it.

Wondering where to get some pipe expanders and the best place to get pipes. Need something to cut them with as well. I see a bunch of different websites but don't know the best materials or thickness to go with. ID? OD? Keep in mind that I need it to go from the stock size from the turbo outlet to a 3 or 4 inch inlet on the muffler. Wastegate with be an internal wastegate dump. Thanks for any ideas. I'll come back to post updates when I have them so ya'll know what it looks like.

 

[slowgsr]

usually 16g tubing works well. i wouldn't recommend trying to slip fit that systems, you can have it welded and the welds won't fail if its done properly. Slip fitting a system like that is going to be difficult.

If it was me, I might build a solid hanger, and use a flex section somewhere in the system.. solid hanger near the end right where it exits the bumper so it dosent bounce around and rub on the bumper.

Just buy tubing from your local exhaust supplier, trying getting some 'U' bends, and you just basically have to picture where you want it to run and start cutting. You can use masking tape to tape parts together, if you need a small bend you can use 'pie' cuts, (require more welding).. and then have it all taped together, cut some of the tape off each section and mark it with a black marker, then you can take it, have it tacked up.. then check fit, then bring it back and have it welded fully. This is how I did my full aluminum exhaust since I don't have the equipment to weld aluminum.

 

[v8s_are_slow]

Why ya saying that you would recommend slip fitting?

 

[slowgsr]

I wouldn't use slip fit, it will be too difficult to get a slip fit at a bend, trust me on this one the other method will turn a much better result in the end. It will also be much easier. Using masking tape will hold the pieces in place very easily, then when your done just take a bit of tape off each joint, mark a 'V' shape and number the pipes then get the all tacked up.

Im not going to bother trying to convince you agaisnt a side exit since its what you want, just trying to help you build a good piece.

 

[v8s_are_slow]

K, thanks for the advice. Not sure why you'd try and talk me out of a side exit exhaust anyway. Don't have to worry about emissions here. Would prefer less weight, and less back pressure anyway. Plus, my car is a GS-T that I'm gonna convert to Awd and don't wanna have to worry about all the hangers and crap. I've wanted a side exit exit for a LONG time. Last exhaust I had stopped right at the bottom of the oil pan. Just want this one to be a little nicer, and a wee bit longer, but not much.

 

[v8s_are_slow]

Have my alternator relocation kit but just have to install it. FP directed me to Spdexhaust.com for the piping I need. Gonna order the pipe for the wastegate dump tube 1st cause I know I need that. When my GI Bill rolls in I'll be trying to get the rest of it but just have to find time to get the relocation kit installed 1st so that I'm able to see what kind of room I have to work with. Sooooo hoping I can use my ATR muffler for this. It sounds so nice. Anyway, I'll post up again when I've actually accomplished something. Lol.

 

[v8s_are_slow]

I know I said about a year ago that I'd be getting this done in a couple of months but it's finally about to happen now. Alternator relocation kit is installed, I have the new bumper and the hole is cut. Dropped off the bumper today to get painted. As soon as that's done, the bumper is going on (next week) and then have to find this guy's number that does exhaust work and paying to have it done....since I don't have a welder handy or the cutting tools needed. I'll post some updates when it's done. I have one of those "muffler" tips I think I'm gonna end up using because the muffler I WAS gonna use seems to take up too much room. Anywho, I'll post pics when I have them. Just wanted to post to let ya'll know this isn't a deadend thread going nowhere.

 

[DashLaflash]

Pics PLEASE when they're available! I'm interested to see how quiet it ends up being. I ran open downpipe for like a week and the cops and neighbors absolutely hated me.

 

[hurricanecris24]

pics would be great i plan on doing the same and trying to get some ideas

 

[richard33]

A little excessive for a DD t28 car?

 

[bNasty]

A little excessive for a DD t28 car?

no such thing!

 

[v8s_are_slow]

It's a sleeper 20g now but heck, i'd do it on a T-25. Ordered the chrome emblem from STM and hoping my bumper will be done on Monday. After that I just have to find a day off to meet up with this guy and get it done. That, and I have to order my piping of course.

 

[v8s_are_slow]

I have my bumper on now. Installed it yesterday. But worried about clearance for the exhaust. I have the alternator relocation kit on but the oil filter housing is still there. Even if I did a front facing filter housing on it, it'd still be there taking up the same space. I have to either go over, or under the filter housing. And I have 3 inch i/c piping. Took some pics but yeah, my engine bay is dirty cause my valve cover is leaking. Just showing some pics to give ya'll an idea but need to throw the choices of tips/muffler choices I have with it in there so ya'll can have a better idea of what I mean.

Old versus new. The old bumper was all busted up badly.

You must be logged in to view this image or video.

You must be logged in to view this image or video.

You must be logged in to view this image or video.

You must be logged in to view this image or video.

And the room I have to work with. I obviously can't do the piping between the i/c piping and the filter housing. If I go over the oil filter housing, I'm gonna have to do a sharp turn down and then out the side towards the end. If I go under the housing, I'm afraid of it going under the frame and hitting the ground at some point.

You must be logged in to view this image or video.

You must be logged in to view this image or video.

I'll post more later.

 

[Jiggalude]

You'll have to come straight down and as far to the bottom of the car as you can without the risk of scraping to clear everything. I don't know how the hell you're going to fit a muffler in there.

 

[v8s_are_slow]

I'll post more pics tomorrow to show the options I'm looking at.

 

[DashLaflash]

Ya I can't see a muffler fitting. Check out Paul Volk's compound turbo thread. He has some pictures on the first page of his exhaust. He has a cutout in the downpipe sending the exhaust out the front bumper.

 

[v8s_are_slow]

I've seen that thread but it's been awhile. Anyway, here's the muffler I was planning to use but I think it might be a little heavy. It's an ATR muffler that I shortened. The body of it is only 6 inches long, but I'd need to shorten the tip as well. I have a couple of tips with the "mufflers" built in (if ya wanna call it that). I'll insert them into the bumper tomorrow to show what kind room and issues I might have. But for now, just a picture of the ATR muffler. Although I don't think I'll be able to use it, I'd LOVE to hear it on a dsm. Sure it'd sound sooooo awesome.

You must be logged in to view this image or video.

 

[hurricanecris24]

I would just use straight pipe

 

[v8s_are_slow]

The possibilty is there, but I don't want to.

 

[dsmrollerz90]

!! I always wanted to do this to my 1g but I still havnt learned how to weld

 

[Jiggalude]

I think that's pretty cool, I just don't see how you'll be able to mount it and support it right there in that little bit of space. Straight pipe is going to be insanely loud. What about a shortened cherry bomb?

 

[v8s_are_slow]

I really wish I would've cut the hole smaller but I didn't know I was gonna have such an issue with room to do this. Anyway, here's the 2 tips. The bigger one fills up the hole really nicely and I'd LOVE to use it but I just think that the length is gonna be too big of an issue because to make room for it, the inlet of the pipe is gonna have to be pointed down more than I care for. Not to mention that it's a 4 inch inlet and getting a pipe that big with such a sharp radius will be next to impossible. So I think I'm gonna have to go with the smaller tip which is a 3 inch inlet and a 4 inch outlet. I'll be using 2 1/2" pipe and it expands to 3 inches right at the inlet on the tip. I may have to make some sort of metal plate to bolt to the bumper as well as serve as protection from any exhaust coming out....and I can make the hole smaller so it's not such a large freakin hole. Anyway, here's the pics of the 2 tips. And yes I bought them slanted so the lines would follow the car more nicely.

You must be logged in to view this image or video.

The larger tip that I really wish I could use.

You must be logged in to view this image or video.

And these 2 are of the smaller tip.

You must be logged in to view this image or video.

You must be logged in to view this image or video.

 

[BlackMount]

You got that from walmart did you? Just. Curious....

 

[v8s_are_slow]

What, the exhaust tip? No, from my work. Pepboys. Unless you're talking about something else. I dunno.

 

[okm12346]

You may want to consider a short route IC piping thru the radiator support. That will free up that space and you can a small size glasspack. i'd say you go with 14'' magnaflow glasspack