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soccerbummer1104 · (This post was last modified: 05-09-2011 04:33 PM by soccerbummer1104.)

UPDATED!!!!
CHECK THE 3rd page for photos and a stationary video!

ok, so its time for me to upgrade my exhaust.
Im doing a full SS catback (already have aftermarket header) 2.5" od the whole way with a cutout that will still go through the tips when opened.

this is the original cad drawing (i didnt connect everything, it was just for conception and angle on the bends i would need)
even though the system is convoluted, it follows the same path as the stock exhaust, but with smoother bends, and better flow
[Image: convolutedexhaust.jpg]

PIPE CAME IN!
[Image: zimg4301small.jpg]

i went with 2.5" in/out vibrant ultra quiet resonators. Even thouth they are straight through, i can screen into these things, and it is of "inside voice" level on the output. and im running three with the valve closed.
[Image: zimg4303small.jpg]

inside the vibrant ultra quiet
[Image: zimg4302small.jpg]

new tips
dual 3.5"out magnaflow corvette c2 style tips
[Image: zimg4304small.jpg]

started cutting last night
quick mock-up, obviously no final cuts, just showing flow pattern to a friend
[Image: zimg4312small.jpg]

closeup of the bottom bend
[Image: zimg4313small.jpg]

made the t and ive already finished the rest of the bends, the ones post cutout are not shown.
[Image: zimg4315small.jpg]

top dead center · (This post was last modified: 01-15-2011 06:24 PM by top dead center.)

Looks nice. Wanna do aome dyno testing?

JB · (This post was last modified: 01-16-2011 08:08 PM by JB.)

Pics from today's fabbing...good job Brad and Richard thats some good work for your first go at exhaust fab!

Deciding and taching

[Image: img8401l.jpg]

And it fits! barely...

[Image: img8418b.jpg]

Richard working on his TIG'ing skills, amazing how much progress was made with only a couple hours worth of welding.

[Image: img8422.jpg]

More was done but its not totally finished yet. I will let Brad chime in on what else needs to be done...

**Clemsons2k** · 01-16-2011, 10:20 PM

Looks like an awesome project thumbsup

soccerbummer1104 · 01-16-2011, 10:43 PM

well i started polishing it up a bit, but still to go, i have to run the 4 foot section of pipe, put a kink in it to get it to go into the middle brace correctly, and then weld in the last resonator just after the header. We also have to finish measuring and cutting the pipe for going out the back of the mini, as well as welding up the exhaust hangers.

moar pictarzzz!
[Image: zsmallimg4320.jpg]

JB · 01-16-2011, 11:20 PM

Did you test fit after putting in the cutout section?

**300zmankellan** · 01-16-2011, 11:51 PM

@ John: Brad says yes

Mpowered · 01-17-2011, 10:13 AM

Killer job with the CAD and fabrication on this! You guys are doing better work in your garage than I've seen at most exhaust shops.

Shon Herron · 01-17-2011, 02:21 PM

sorry that I am not up on everyones rides and projects, can barely keep up with my own but what is this going on!?!?
and there might be some pix within the post that are not showing up that would tell me exactly what I am looking for but on this network it blocks most pix....

zps2004 · 01-17-2011, 02:42 PM

Brad, can you weigh both of them when your done with yours. I want to see how much each weighs.

JB · (This post was last modified: 01-17-2011 05:40 PM by JB.)

(01-17-2011 02:21 PM)Shon Herron Wrote: sorry that I am not up on everyones rides and projects, can barely keep up with my own but what is this going on!?!?
and there might be some pix within the post that are not showing up that would tell me exactly what I am looking for but on this network it blocks most pix....

Lol pics helps a lot in this thread. Find a comp that supports them else this thread will suck Tongue

Shon Herron · 01-17-2011, 05:46 PM

got home and see them, but still not sure what car, LMAO
BUT, why is there 2 or 3 mufflers??? and looped like that!?!?
looking for some education here....

soccerbummer1104 · 01-17-2011, 06:13 PM

well hopefully you can see all the pictures when you get home.
But i designed and am in the process of fabricating an exhaust for my supercharged mini cooper S.
The exhaust is a 2.5" from the header collector back, with a straight through resonator (they are surprisingly very quiet) post cat. The exhaust then goes through 4 feet of tubing where it comes to a t section.
On one side of this t section is a cutout, and the other side it goes through 2 more straight through resonators before joining up with the other side of the cutout, before going out the back of the car.
In effect (its an electric cutout) i will have the option of either having an exhaust with just one resonator post cat to eliminate rasp, but still go out the back of the car through the tips if the cutout is open, or if i have the cutout closed, the exhaust will go through 3 resonators and several bends to quiet the car down to make it pleasant on the road.

**Clemsons2k** · 01-17-2011, 10:22 PM

I love the design just one question. How would you keep the exhaust gases from going through the other two resonators anyways once the cutout is open? All thats gonna do is increase sound, not velocity (i.e. more power). Or is the power thing not the point of this project?

JB · (This post was last modified: 01-17-2011 10:35 PM by JB.)

(01-17-2011 10:22 PM)Clemsons2k Wrote: I love the design just one question. How would you keep the exhaust gases from going through the other two resonators anyways once the cutout is open? All thats gonna do is increase sound, not velocity (i.e. more power). Or is the power thing not the point of this project?

Fluid flows in the path of least resistance...the Y he made looked very efficient for flowing through the cutout, so I'm pretty sure back-pressure will be decreased when the cut out it open. Decreased velocity at low RPM's yes, however increased at high revs from the lower "drag". It might still flow through the mufflers a bit, but why when its easier to go through the same size piping that is shorter and without resonators?

No engineer but Josh taught me well Tongue