So the time has come to change my exhaust. The stock one is so full of holes that I can see through it sideways. It no longer attracts magnets because there is no more steel, just rust. With such a scenario there's obviously nothing to weld. My Y pipes are also a bit punctured. And to make matters worse, I don't have access here to all those funky Manaflow, Borla or EMS exhausts.
My only option is to fabricate the exhaust myself. I have some minor MIG welding experience, a TIG welder is on it's way, I also have a plasma cutter and some other tools. I also have access to 304 stainless steel.
My initial thoughts:
1. Make it a 3" diameter. The difference in tubing price is not so big.
2. The stock center muffler annoys me because it's huge. I am planning to use a muffler similar to the 'Moroso spiral muffler'. Does anybody have experience with this muffler design? My plan is to run the tubing and muffler on the outside of the frame so that I have free space for a gas subtank or maybe something else in place of the stock muffler. I would greately appreciate any comments on the spiral flow muffler design.
3. Go stainless from Y pipe to tip. With SS I will not have to ever think about the exhaust again.
4. I have two new Magnaflow cats. They are three-way and the universal type. I am planning to run two of those side by side to make sure I don't have much air restrictions. One O2 sensor before the cats and one after.
I am currently looking for criticism, inspiration or a pat in the back meaning that I am going in the right direction.
And one question: I've seen that many exhaust tubes are lap-welded. The tube ends are stretched so that two tubes connect and are welded around. I have no access to a machine which would let me stretch tubes so I will have to butt-weld them. Will it be strong enough?
Butt weld vs lap weld below:
My only option is to fabricate the exhaust myself. I have some minor MIG welding experience, a TIG welder is on it's way, I also have a plasma cutter and some other tools. I also have access to 304 stainless steel.
My initial thoughts:
1. Make it a 3" diameter. The difference in tubing price is not so big.
2. The stock center muffler annoys me because it's huge. I am planning to use a muffler similar to the 'Moroso spiral muffler'. Does anybody have experience with this muffler design? My plan is to run the tubing and muffler on the outside of the frame so that I have free space for a gas subtank or maybe something else in place of the stock muffler. I would greately appreciate any comments on the spiral flow muffler design.
3. Go stainless from Y pipe to tip. With SS I will not have to ever think about the exhaust again.
4. I have two new Magnaflow cats. They are three-way and the universal type. I am planning to run two of those side by side to make sure I don't have much air restrictions. One O2 sensor before the cats and one after.
I am currently looking for criticism, inspiration or a pat in the back meaning that I am going in the right direction.
And one question: I've seen that many exhaust tubes are lap-welded. The tube ends are stretched so that two tubes connect and are welded around. I have no access to a machine which would let me stretch tubes so I will have to butt-weld them. Will it be strong enough?
Butt weld vs lap weld below: