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    Thread: Custom Exhaust : It Begins

    1. Member Draxus's Avatar
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      08-18-2010 08:17 PM #1
      No going back now. Burns Stainless is fabing up my 2-to-1 collector as I type.


      Need to order:

      O2 Bungs
      V-Bands
      Mandrel Bends
      308 Tig Rod
      304 Stainless Flatbar - So I can mill out the header/testpipe flange.

      Just ordered:

      SM-300-450-17

      Inlet/Outlet Diameter: 3.00"
      Body Outer Diameter: 4.50"
      Overall Length: 17"
      Weight (lb): 3.29

      http://www.burnsstainless.com/sm-300-450-17.aspx





      and



      2-to-1

      Inlet Diameter: 2.25"
      Outlet Diameter: 3"





      I am debating on putting in two venturi vacuum generators in the test-pipe. Not sure yet.

      These:

      http://vibrantperformance.com/catalo...oducts_id=1243

      Quote Originally Posted by BlownR View Post
      I have seen several open slots, usually after tequila. Wait, I think that's different.
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    2. Member jamezracer's Avatar
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      08-18-2010 08:29 PM #2


      looks good so far. any particular plans for sound or are you just seeing where the project takes you?

      I wish I could weld, this looks like a fantastic project.
      As an engineer I tend to start with a perfectly functional car, then keep fixing it until it's broken.

    3. Member Draxus's Avatar
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      08-18-2010 08:39 PM #3
      Quote Originally Posted by jamezracer View Post


      looks good so far. any particular plans for sound or are you just seeing where the project takes you?

      I wish I could weld, this looks like a fantastic project.
      Well, Burns Mufflers take out a huge amount of rasp. So it should be interesting.

      I am going to dump it right before the rear diff, and see how it sounds. Based on that, I will pick my next size of muffler.
      Quote Originally Posted by BlownR View Post
      I have seen several open slots, usually after tequila. Wait, I think that's different.
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    4. Senior Member PowerDubs's Avatar
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      08-18-2010 09:26 PM #4
      More specific details?

      Burns stuff is pricey.
      -Josh
      Current- 06 Phaeton 4-seater 6.0 W12 | 04 VW R32 | 03 Gti 24v VR6 | 00 M Roadster | 12 Kia Soul 1.6 stick | 01 ZRX1200R | 03 KLX400R
      Past- too much too list.

    5. Member Draxus's Avatar
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      08-19-2010 03:39 AM #5
      Quote Originally Posted by PowerDubs View Post
      More specific details?

      Burns stuff is pricey.
      Yea, it was a bit more than other stuff. But the extra cost went towards the quality of the product. I can also repack the muffler just by undoing 4 hex bolts. So it will never wear out, and I can play with different packing materials to get the sound I want!

      Details:

      I bought some stock downpipes from a fellow on here and took them over to my buddies machine shop. He does 5-axis milling for Boeing, awesome place. We threw the downpipes on the CMM machine and pulled all of the X,Y,Z dims and I then made up the exhaust flange in Solidworks. I also have the X,Y,Z and I,J,K of the downpipe to testpipe and then the downpipes to 3-to-1 "headers". So someone could make downpipes and have them mandrel bent. Anyway, that is a project for another day.

      So, I made the flange with 2.25" exits.

      From there back it will be 2.25" OD piping back to the first exhaust hanger. It is important to note that these pipes are not bent like the stock ones or all the other aftermarket testpipes. They are straight back to keep the tubes equal length and not screw with the exhaust pulses.

      At that point it merges with the Burns 2-to-1 into a 2.75" single and then a megaphone to 3". V-Band.

      From there it will go back and up slightly and tuck the muffler into the stock location.

      I am going to pipe it up past the diff and get it ready for the final muffler.

      The final muffler is for another project but what I am thinking is having another Burns piped out to the passenger side exit. Then getting a bigger exhaust flapper for the driver side. So the flapper would fully bypass the muffler, but when it was closed only the passenger side would flow.

      Sorry if that is horribly written. I am tired and have drank quite a bit of whiskey. haha
      Quote Originally Posted by BlownR View Post
      I have seen several open slots, usually after tequila. Wait, I think that's different.
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    6. Member BOUDAH's Avatar
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      08-19-2010 04:25 AM #6
      HAHA, thats actually sounds good man, i cannot wait to seee this through

    7. Member GinsterDub's Avatar
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      08-19-2010 11:38 AM #7
      as you are a local, i cant wait to see it in person and hear it.

    8. Member Draxus's Avatar
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      08-26-2010 05:00 PM #8
      Should get my parts today!

      So excited!
      Quote Originally Posted by BlownR View Post
      I have seen several open slots, usually after tequila. Wait, I think that's different.
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    9. Member Draxus's Avatar
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      08-28-2010 04:16 AM #9
      OMG

      So worth the money. Everything is perfect. The welds are phenomenal! Sweet Jesus look at the Y-Pipe! Its mandrel bent to size! Oh yea, stickers also! Sorry about the phone pics.













      Quote Originally Posted by BlownR View Post
      I have seen several open slots, usually after tequila. Wait, I think that's different.
      MKIV DBP .:R32 | Photo Gallery
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    10. Junior Member Dingman1088's Avatar
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      08-28-2010 04:55 AM #10
      Looks bad ass......Good quality welds

    11. Member KoolTrix's Avatar
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      08-28-2010 07:03 PM #11
      ...waiting.
      Black Magic R32 - Driver Mod
      RAWR - it means i love you in wookie

    12. Member dr. b's Avatar
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      08-28-2010 09:37 PM #12
      the inside-shot of that 2-1 gave me a half-stack.


      subscribed!
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    13. Member vwgeorge2's Avatar
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      08-28-2010 10:09 PM #13
      Dude, very cool.....


      http://forums.vwvortex.com/showthrea...-final-fantasy....

      Stage 7= VF, HPA= V7-ysi, A/W Intake, Dual Jet Water/Meth, UM E-85 Flex 870cc, ProMAF, 268 Cams, SS Header, SS Mid pipe, Custom intake, Brisk plugs, Lambo flapper

    14. Member Det. John Kimble's Avatar
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      08-29-2010 01:02 AM #14
      Quote Originally Posted by GinsterDub View Post
      as you are a local, i cant wait to see it in person and hear it.


      x2

    15. Member Draxus's Avatar
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      08-29-2010 03:10 AM #15
      Quote Originally Posted by dr. b View Post
      the inside-shot of that 2-1 gave me a half-stack.


      subscribed!
      Bahahaha. Glad I can get you where you need to go.

      Quote Originally Posted by Det. John Kimble View Post
      x2
      Nice meeting you today mate. I am going to mug you for your wheels!
      Quote Originally Posted by BlownR View Post
      I have seen several open slots, usually after tequila. Wait, I think that's different.
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    16. Member Det. John Kimble's Avatar
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      08-30-2010 04:49 PM #16
      Quote Originally Posted by Draxus View Post



      Nice meeting you today mate. I am going to mug you for your wheels!


      lol

      It was great meeting you and Jess too. Looking forward to seeing this when you are all done

    17. Member GT42R32deepblue's Avatar
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      08-30-2010 06:47 PM #17
      yes i drive a vw
      turbo R32 12.8 @98mph (~410hp@9lbs)

    18. Member TurboREX's Avatar
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      08-30-2010 07:13 PM #18
      Quote Originally Posted by GT42R32deepblue View Post
      damn thats loud

    19. Member 04R32lover's Avatar
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      08-30-2010 07:53 PM #19
      I've been thinking of a custom set up for a while now, i can't wait to see how this sounds after it's all done.
      RS .:R

    20. Member Draxus's Avatar
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      08-31-2010 01:47 AM #20
      Wow. That sounds deep and loud.

      Should be interesting. lol
      Quote Originally Posted by BlownR View Post
      I have seen several open slots, usually after tequila. Wait, I think that's different.
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    21. Member LadiesMan's Avatar
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      08-31-2010 04:39 PM #21
      Quote Originally Posted by GT42R32deepblue View Post
      lol sounds like a lion imo

    22. Member Draxus's Avatar
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      09-08-2010 01:54 AM #22
      Picked up 10' of 2.25" 304 DOM and 21"x.5"x5" 304 flatbar.

      I am stoked because the 10' of DOM only cost me $40 bucks.

      God damn. Flatbar is kinda pricey lately though.

      Got my 308 tig rod and some new gloves too!

      Quote Originally Posted by BlownR View Post
      I have seen several open slots, usually after tequila. Wait, I think that's different.
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    23. Member BOUDAH's Avatar
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      09-08-2010 03:03 AM #23
      ur project has been an inspiration for mine

    24. Member Draxus's Avatar
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      09-09-2010 02:56 AM #24
      Put the car up on lift today to get a look at it. All going to work well.

      After looking at it. I think I am going to go with a single exhaust out and put a tow hook in the passenger whole for lapping days.

      Not too sure yet.

      Hope to cut out the flange tomorrow or Friday. Start welding on weekend.
      Quote Originally Posted by BlownR View Post
      I have seen several open slots, usually after tequila. Wait, I think that's different.
      MKIV DBP .:R32 | Photo Gallery
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    25. Member BOUDAH's Avatar
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      09-09-2010 03:44 AM #25
      Just make sure you do something with the side you dont use...IMO it looks off when you dont fill the hole or in your case you said u wanted to add a tow hook

    26. Member dr. b's Avatar
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      09-13-2010 11:37 AM #26
      i heard you were driving the caR again.....where are the updates/pics? let's see what's been done!
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    27. Member Draxus's Avatar
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      09-13-2010 01:39 PM #27
      Not done yet. Don't worry.
      Quote Originally Posted by BlownR View Post
      I have seen several open slots, usually after tequila. Wait, I think that's different.
      MKIV DBP .:R32 | Photo Gallery
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    28. Member Draxus's Avatar
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      09-13-2010 04:31 PM #28
      3" U-Bends, V-Band, and O2 Sensor Bungs on the way.
      Quote Originally Posted by BlownR View Post
      I have seen several open slots, usually after tequila. Wait, I think that's different.
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    29. Member huichox4's Avatar
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      09-13-2010 06:45 PM #29
      Quote Originally Posted by Draxus View Post
      3" U-Bends, V-Band, and O2 Sensor Bungs on the way.
      I cut my 02 sensor bungs from the stock piece and re used them not the cleanest but a perfect fit

      my whole exhaust was done with an arch welder and a 4 day experienced guy >>>>>> Me so not the cleanest/good looking job. it works though.

      you seem to be going for some quality piece that works and for show

    30. Member Draxus's Avatar
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      09-13-2010 06:47 PM #30
      Yea, I want it 100% 304 stainless. I am kinda psycho like that. lol
      Quote Originally Posted by BlownR View Post
      I have seen several open slots, usually after tequila. Wait, I think that's different.
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    31. Member huichox4's Avatar
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      09-13-2010 08:50 PM #31
      Quote Originally Posted by Draxus View Post
      Yea, I want it 100% 304 stainless. I am kinda psycho like that. lol
      nothing wrong with that I say. I am so inclined to DIY stuff and dont mind how bad it looks as long as it performs that I may confess that there might be 3 or 4 different steels throughout my exhaust

    32. Member dr. b's Avatar
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      09-14-2010 06:30 PM #32
      yeah, i have to run to the local circle-track shop to pick up some O2 bungs this week so i can get them lined up before i have my DP finish-welded. sucks trying to remember (and then hem up) all the little details.

      i'm stoked to see how your exhaust turns out.
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    33. Member huichox4's Avatar
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      10-14-2010 10:59 PM #33
      how did it go with this?

      no updates in a looooong time man

    34. Member Draxus's Avatar
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      10-14-2010 11:04 PM #34
      Really sorry about the lack of updates guys.

      Started school up and have not had a chance to install anything. I was going to use a buddies TIG machine, but it is turning into a pain because the only time it is available is really odd hours and without warning. Not to mention it's 1+hr away. From where I live now.

      So, yesterday I made some calls and might have my buddy just do it for me. At least he has a lift and I wont have to crawl around. lol



      Oh yea, and some asian lady thought it would be cool to take out my passenger fender on the freway. So I am trying to deal with that.

      Quote Originally Posted by BlownR View Post
      I have seen several open slots, usually after tequila. Wait, I think that's different.
      MKIV DBP .:R32 | Photo Gallery
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    35. Member huichox4's Avatar
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      10-14-2010 11:16 PM #35
      ohh man sorry to hear that .... hope you get that resolved soon

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