DIY Custom exhaust

***fiji06si13*** · 02-07-2007, 08:18 PM

This is for all of those who can't afford to buy a $300+ axel back or exhaust.
I will be doing this piece by piece so bare with me. Some of my parts aren't in yet. Below are pictures of measurments (I know they are corny but they helped out alot).
picture 1:

picture 2: (new exhaust)

Here is a picture of parts I got from a local exhaust shop (Thank you Midas):

You can't use the stock axel back because the outlet pipe is offset to far to right and up. So rather than modify that i will be starting fresh.
The parts are:
2 pre bent pipes to create angle I need
2 1/4 to 2 1/2 Cupler
2 inch to 2 1/4 Cupler
2 1/4 exhaust flange
2 inch to 2 inch Cupler
2 8 inch threaded rods to use as hangers for muffler (will bend with torch)
2 3/8 nuts (all hardware is Galvanized)
2 3/8 washers
I will take measurments after welded and assembled.
Picture Assembled not welded:

This is all I have for now muffler didn't come yet. Will keep you posted.
The total so far on parts is around 30 bucks
The muffler costs 31 bucks
Total 61 dollars.
I will be going to track to do:
3 runs stock
3 runs new exhaust W/silencer in
3 runs no silencer
If it doesn't give me performance i will start from scratch. LOL
Here are pix of flange pressed to outlet pipe.

In this picture it shows you the tapered edge so I can use the stock exhaust gasket.

Assembled long view one:

Assembled long view two:

Now all I need is muffler and a good welding some assembly and all done!

Got the muffler!

Im going to have to add 2 more screws to keep silencer centered.

Assembled on floor!

Outlet view

inlet view

The next Pictures are the muffler and piping hung under the car with some Zip ties, Sharpie marker and alot of patience...........

picture 1

picture 2

picture 3

Finally picture 4

Note: I did this so I can get precise measurements for final weld and build.
I will be welding the pieces together monday night!

Here are the pix of welded exhaust:

I have to grind the welds we ran out of oxygen in the tank so we had to make do....
Nothing a diegrinder can't fix!.
I will also be changing the hanger setup to a different type of rod so it is easyer to bend.
Unfortunately I found out the hard way but that is what this is all about.
Final weld pictures

Video's
Drive by:

Cold start in morning:

skittleslegend · 02-07-2007, 08:25 PM

Rep given to someone doing something new around the 8th :)

**twistedframe** · 02-07-2007, 08:31 PM

great idea, but i would get some mandrel bent tubes. The way those tube are bent with increase exhaust turbulence which may actually lose you some power. Other than that it looks great!

***fiji06si13*** · 02-07-2007, 08:34 PM

Quote:

Originally Posted by twistedframe

great idea, but i would get some mandrel bent tubes. The way those tube are bent with increase exhaust turbulence which may actually lose you some power. Other than that it looks great!

yeah i know but that would cost more money at that point you should just get
a axel back you know. If it does hurt power i will redo the piping. we will see lol!

JeShUa · 02-08-2007, 01:42 AM

I'm not trying to bash because this could potentially turn out nice...
but if you cant afford to mod your car right.. leave it stock.. because stock is better than ghetto

***fiji06si13*** · 02-08-2007, 01:52 PM

Quote:

Originally Posted by JeShUa

I'm not trying to bash because this could potentially turn out nice...
but if you cant afford to mod your car right.. leave it stock.. because stock is better than ghetto

See the thing is is I can buy/afford a $300 exhaust.
I'm doing this for fun. Anyone can buy a axel back and put it on. I would rather make my own and see how it is.
It's only 60 bucks down the tube and last I checked you could spend more than that at a night in the tity bar.
Plus who says it isn't right?

FG*SQUAD Nick · 02-08-2007, 01:57 PM

Quote:

Originally Posted by skittleslegend

Rep given to someone doing something new around the 8th :)

amen rep given to you and skittles :)

***fiji06si13*** · 02-09-2007, 03:47 PM

I wanted to thank all of who is supporting me on this matter and for giving me rep. I'll have more pix soon.....

rmfa · 02-09-2007, 04:23 PM

+1 Thanks for doing something different, I applaud your enthusiasm and your ingenuity.

projectprelude · 02-09-2007, 08:17 PM

props...

***fiji06si13*** · 02-09-2007, 08:37 PM

I hope you guys like the muffler I chose it goes well with the car as long as all goes well.

The tip should go nice with the color of my car.

BLU BY U · 02-10-2007, 08:23 AM

i like your idea, except for not using mandrel bends......lets see how it turns out though.

***fiji06si13*** · 02-11-2007, 10:48 PM

I will be cutting the pipe that will except flange 2 morrow and put the pix up in evening. I will be doing this to create a tapered edge for the gasket to seat to.:)

hoanger · 02-11-2007, 11:13 PM

that is pretty sweet
i hope it turns out good dude
good luck

***fiji06si13*** · 02-12-2007, 07:17 PM

Look at begining photos more pix on DIY!

***fiji06si13*** · 02-12-2007, 08:19 PM

Quote:

Originally Posted by hoanger

that is pretty sweet
i hope it turns out good dude
good luck

Thanx

***fiji06si13*** · 02-12-2007, 08:21 PM

Quote:

Originally Posted by BLU BY U

i like your idea, except for not using mandrel bends......lets see how it turns out though.

Yeah this is just a prototype once I get correct measurements I will have exhaust shop make me one bent tube.

BLU BY U · 02-12-2007, 08:29 PM

keep us updated my fellow fiji owner

***fiji06si13*** · 02-12-2007, 09:14 PM

Quote:

Originally Posted by BLU BY U

keep us updated my fellow fiji owner

Yuppers!

***fiji06si13*** · 02-13-2007, 09:40 PM

Take a look! 1st page bottom of pix!

02-07-2007, 08:18 PM	#1 (permalink)
*fiji06si13* Franken Car Join Date: May 2006 Location: In the same place you were 3 days ago Age: 28 Posts: 8,770 Justin aka Mr. JT iTrader: 3 / 100%	DIY Custom exhaust This is for all of those who can't afford to buy a $300+ axel back or exhaust. I will be doing this piece by piece so bare with me. Some of my parts aren't in yet. Below are pictures of measurments (I know they are corny but they helped out alot). picture 1: picture 2: (new exhaust) Here is a picture of parts I got from a local exhaust shop (Thank you Midas): You can't use the stock axel back because the outlet pipe is offset to far to right and up. So rather than modify that i will be starting fresh. The parts are: 2 pre bent pipes to create angle I need 2 1/4 to 2 1/2 Cupler 2 inch to 2 1/4 Cupler 2 1/4 exhaust flange 2 inch to 2 inch Cupler 2 8 inch threaded rods to use as hangers for muffler (will bend with torch) 2 3/8 nuts (all hardware is Galvanized) 2 3/8 washers I will take measurments after welded and assembled. Picture Assembled not welded: This is all I have for now muffler didn't come yet. Will keep you posted. The total so far on parts is around 30 bucks The muffler costs 31 bucks Total 61 dollars. I will be going to track to do: 3 runs stock 3 runs new exhaust W/silencer in 3 runs no silencer If it doesn't give me performance i will start from scratch. LOL Here are pix of flange pressed to outlet pipe. In this picture it shows you the tapered edge so I can use the stock exhaust gasket. Assembled long view one: Assembled long view two: Now all I need is muffler and a good welding some assembly and all done! Got the muffler! Im going to have to add 2 more screws to keep silencer centered. Assembled on floor! Outlet view inlet view The next Pictures are the muffler and piping hung under the car with some Zip ties, Sharpie marker and alot of patience........... picture 1 picture 2 picture 3 Finally picture 4 Note: I did this so I can get precise measurements for final weld and build. I will be welding the pieces together monday night! Here are the pix of welded exhaust: I have to grind the welds we ran out of oxygen in the tank so we had to make do.... Nothing a diegrinder can't fix!. I will also be changing the hanger setup to a different type of rod so it is easyer to bend. Unfortunately I found out the hard way but that is what this is all about. Final weld pictures Video's Drive by: Cold start in morning: Last edited by fiji06si13; 03-01-2007 at 09:30 PM.

02-09-2007, 08:37 PM	#11 (permalink)
*fiji06si13* Franken Car Join Date: May 2006 Location: In the same place you were 3 days ago Age: 28 Posts: 8,770 Justin aka Mr. JT iTrader: 3 / 100%	I hope you guys like the muffler I chose it goes well with the car as long as all goes well. The tip should go nice with the color of my car. Last edited by fiji06si13; 02-09-2007 at 08:51 PM.

02-11-2007, 10:48 PM	#13 (permalink)
*fiji06si13* Franken Car Join Date: May 2006 Location: In the same place you were 3 days ago Age: 28 Posts: 8,770 Justin aka Mr. JT iTrader: 3 / 100%	flange and gasket surface I will be cutting the pipe that will except flange 2 morrow and put the pix up in evening. I will be doing this to create a tapered edge for the gasket to seat to.:)

02-12-2007, 07:17 PM	#15 (permalink)
*fiji06si13* Franken Car Join Date: May 2006 Location: In the same place you were 3 days ago Age: 28 Posts: 8,770 Justin aka Mr. JT iTrader: 3 / 100%	More pix! Flange pressed to tapered pipe! Look at begining photos more pix on DIY!

02-13-2007, 09:40 PM	#20 (permalink)
*fiji06si13* Franken Car Join Date: May 2006 Location: In the same place you were 3 days ago Age: 28 Posts: 8,770 Justin aka Mr. JT iTrader: 3 / 100%	Muffler came in new pix final assembly before welding! Take a look! 1st page bottom of pix!

02-07-2007, 08:25 PM	#2 (permalink)
skittleslegend Senior Member Member Join Date: Sep 2005 Location: Stowe, Vermont Age: 23 Posts: 7,833 iTrader: 1 / 100%	Rep given to someone doing something new around the 8th :)

02-08-2007, 01:42 AM	#5 (permalink)
JeShUa Senior Member Join Date: Apr 2006 Posts: 12,196 Keepin` it Phresh iTrader: 11 / 100%	I'm not trying to bash because this could potentially turn out nice... but if you cant afford to mod your car right.. leave it stock.. because stock is better than ghetto

02-09-2007, 03:47 PM	#8 (permalink)
*fiji06si13* Franken Car Join Date: May 2006 Location: In the same place you were 3 days ago Age: 28 Posts: 8,770 Justin aka Mr. JT iTrader: 3 / 100%	I wanted to thank all of who is supporting me on this matter and for giving me rep. I'll have more pix soon.....

02-09-2007, 04:23 PM	#9 (permalink)
rmfa Senior Member Join Date: Sep 2006 Location: Austin, TX Age: 27 Posts: 3,237 Ronnie iTrader: 2 / 100%	+1 Thanks for doing something different, I applaud your enthusiasm and your ingenuity.

02-09-2007, 08:17 PM	#10 (permalink)
projectprelude Senior Member Join Date: Jan 2007 Location: wooster , ohio Posts: 2,388 Aaron iTrader: 3 / 100%	props...

02-10-2007, 08:23 AM	#12 (permalink)
BLU BY U Senior Member Join Date: Apr 2006 Age: 24 Posts: 7,375 iTrader: 1 / 100%	i like your idea, except for not using mandrel bends......lets see how it turns out though.

02-11-2007, 11:13 PM	#14 (permalink)
hoanger Senior Member Join Date: Apr 2006 Location: Calgary, Alberta Posts: 4,438 Jason iTrader: 1 / 100%	that is pretty sweet i hope it turns out good dude good luck

02-12-2007, 08:29 PM	#18 (permalink)
BLU BY U Senior Member Join Date: Apr 2006 Age: 24 Posts: 7,375 iTrader: 1 / 100%	keep us updated my fellow fiji owner

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