Well my project started back in January with building the 2 into 1 crossover for a pair of rams horn manifolds with 2.5" outlets.
Then it was time to figure out which muffler and how much exhaust pipe was needed to build the rest. After much research and soul searching I decided to go with Flowmaster's 50 Series HD #953559 which is Aluminzed steel with offset 3.5" inlet and outlet.
For exhaust pipe I opted for Vibrant Performance #12612 3.5" OD AS U-J mandral bent tube.
I built a cardboard template of the pipe shape to determine the cut locations.
The green lines are reference only and used to plot the cut angles. They were where the straight pipe ended or began. While this doesn't look like enough pipe it actually was perfect and every inch was used without any additional pipe or modifications. To build the connector pipe between the Y-collector and the muffler I used the 13" section and the section between the 90 and 22.5 degree marks rotated 180 degrees. This came close to the up angle of the frame. The tail pipe was built with 21" section mated to the 7" section with the section between the 45 and 90 degree for the turn down on the end.
To join all the components I used 3.5" V-band sets from Pacific Performance Engineering. I also used two or their 3" T-bolt clamps to connect to my original dual exhaust hangers on the drivers side. This is what I ended up with.
I'd never used V-band clamps before but liked the way they locked everything into place. It took a few minor adjustments with pipe line up starting from the front and working to the rear. Once everything was aligned and tightened it was all rock solid. I now know that it will go back together perfectly after disassembly, a little more weld clean up and then a complete high temp paint job. I actually lucked out with the hangers from my original exhaust lining up with the new system.
For those of you who may have contemplated build your own exhaust I say go for it. My system was built with all mandrel bent tubing which probably made things easier as the angles were good. I used a portable band saw from HF to make the straight cuts through the pipes. As they say measure twice and cut once. I probably measured three or more times.
Slip fits on the front crossover section was easier to align and weld than the rear butt welds. My MIG welding is not the best and I did actually burn a couple of small holes through the 14 gauge pipe but nothing a little more spot welding couldn't fix.
Then it was time to figure out which muffler and how much exhaust pipe was needed to build the rest. After much research and soul searching I decided to go with Flowmaster's 50 Series HD #953559 which is Aluminzed steel with offset 3.5" inlet and outlet.
For exhaust pipe I opted for Vibrant Performance #12612 3.5" OD AS U-J mandral bent tube.
I built a cardboard template of the pipe shape to determine the cut locations.
The green lines are reference only and used to plot the cut angles. They were where the straight pipe ended or began. While this doesn't look like enough pipe it actually was perfect and every inch was used without any additional pipe or modifications. To build the connector pipe between the Y-collector and the muffler I used the 13" section and the section between the 90 and 22.5 degree marks rotated 180 degrees. This came close to the up angle of the frame. The tail pipe was built with 21" section mated to the 7" section with the section between the 45 and 90 degree for the turn down on the end.
To join all the components I used 3.5" V-band sets from Pacific Performance Engineering. I also used two or their 3" T-bolt clamps to connect to my original dual exhaust hangers on the drivers side. This is what I ended up with.
I'd never used V-band clamps before but liked the way they locked everything into place. It took a few minor adjustments with pipe line up starting from the front and working to the rear. Once everything was aligned and tightened it was all rock solid. I now know that it will go back together perfectly after disassembly, a little more weld clean up and then a complete high temp paint job. I actually lucked out with the hangers from my original exhaust lining up with the new system.
For those of you who may have contemplated build your own exhaust I say go for it. My system was built with all mandrel bent tubing which probably made things easier as the angles were good. I used a portable band saw from HF to make the straight cuts through the pipes. As they say measure twice and cut once. I probably measured three or more times.
Slip fits on the front crossover section was easier to align and weld than the rear butt welds. My MIG welding is not the best and I did actually burn a couple of small holes through the 14 gauge pipe but nothing a little more spot welding couldn't fix.
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although I'd like it with a 70 series muffler, I'd be concerned 50 series would be too loud.
