Custom Exhaust : It Begins

[Draxus]

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

[jamezracer]

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.

[Draxus]

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.

[PowerDubs]

More specific details?

Burns stuff is pricey.

[Draxus]

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

[BOUDAH]

HAHA, thats actually sounds good man, i cannot wait to seee this through

[GinsterDub]

as you are a local, i cant wait to see it in person and hear it.

[Draxus]

Should get my parts today!

So excited!

[Draxus]

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.

[Dingman1088]

Looks bad ass......Good quality welds

[KoolTrix]

...waiting.

[dr. b]

the inside-shot of that 2-1 gave me a half-stack.


subscribed!

[vwgeorge2]

Dude, very cool.....

[Det. John Kimble]

as you are a local, i cant wait to see it in person and hear it.

x2

[Draxus]

the inside-shot of that 2-1 gave me a half-stack.


subscribed!

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

x2

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

[Det. John Kimble]

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

[GT42R32deepblue]

heres what i did 4 years ago...
http://forums.vwvortex.com/showthrea...custom-exhaust

[TurboREX]

heres what i did 4 years ago...
http://forums.vwvortex.com/showthrea...custom-exhaust

damn thats loud

[04R32lover]

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.

[Draxus]

Wow. That sounds deep and loud.

Should be interesting. lol

[LadiesMan]

heres what i did 4 years ago...
http://forums.vwvortex.com/showthrea...custom-exhaust

lol sounds like a lion imo

[Draxus]

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!

[BOUDAH]

ur project has been an inspiration for mine

[Draxus]

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.

[BOUDAH]

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

[dr. b]

i heard you were driving the caR again.....where are the updates/pics? let's see what's been done!

[Draxus]

Not done yet. Don't worry.

[Draxus]

3" U-Bends, V-Band, and O2 Sensor Bungs on the way.

[huichox4]

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

[Draxus]

Yea, I want it 100% 304 stainless. I am kinda psycho like that. lol

[huichox4]

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

[dr. b]

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.

[huichox4]

how did it go with this?

no updates in a looooong time man

[Draxus]

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.

[huichox4]

ohh man sorry to hear that .... hope you get that resolved soon