Building A Custom True 3 Inch Exhaust in my garage
06-07-2012, 12:57 AM
#1
Building A Custom True 3 Inch Exhaust in my garage
Gents, I decided to take the plunge and try to build my own custom exhaust system. However, I humbly ask for your guidance ... in return ... pics of my build.
But first, some background
BackGround:
There are two reasons behind this build.
Reason 1: Currently I have a racing beat midpipe followed up by a MS 2 canister catback. Although this set-up sounds great, it is less than ideal for performance. The flanges are 2.5 inch, the midpipe is 3 inch, and the catback is 2.5 inch.
Therefore, I want to build a true 3 inch header back exhaust all the way - 3 inch flanges - 3 inch piping.
Reason 2: I have very little welding experience (a bit of arc experience). However, my personal research and experience has led me to believe that if you want something done right, you either have to do it yourself or pay someone a lot of money (which I do not have). Eventually I want to build a completely custom low mount turbo system, and I want this build to be practice/learning to weld.
Owning the rx8 has been one huge learning experience. Three years ago, I barely knew how to do an oil change. By now, I am proud to say that I have either assited or have taken apart almost everything short of parts of the interior and the transmission itself. I think it is time for me to step up my game and enter the fab world.
What I am I thinking
- True 3 inch, single exit, possibly twin, but I have not decided
- One Spiral Style Resonator
- One Muffler
- Bolts up to stock header, 2 or 3 pieces (akin to stock)
Tools I need
- Welder - I know TIG is expensive, and I have been doing some research on it. I would really like your guys opinions in this area. Should I buy new? Used? Supplies I will need as well as running costs ... I am thinking 1 - 1.5k for this
- Pipe Cutter - same as above except for the price range. Where do I even find one?
- Pipe Bender? - I found some pre bent pipe kits online... see below for specific one I am looking at.
Parts I am looking at
- Piping: This (needs to be bent http://www.summitracing.com/parts/SUM-640030/)
OR http://www.summitracing.com/parts/FLO-15902/
- Resonator: http://www.summitracing.com/parts/MOR-94051/
- Muffler: http://www.summitracing.com/parts/SUP-546-3019/
- Header Flange: can you help me locate one?
- Midpipe Flanges:
Can I use ebay for flanges?
I plan on starting this in a month or so.
But first, some background
BackGround:
There are two reasons behind this build.
Reason 1: Currently I have a racing beat midpipe followed up by a MS 2 canister catback. Although this set-up sounds great, it is less than ideal for performance. The flanges are 2.5 inch, the midpipe is 3 inch, and the catback is 2.5 inch.
Therefore, I want to build a true 3 inch header back exhaust all the way - 3 inch flanges - 3 inch piping.
Reason 2: I have very little welding experience (a bit of arc experience). However, my personal research and experience has led me to believe that if you want something done right, you either have to do it yourself or pay someone a lot of money (which I do not have). Eventually I want to build a completely custom low mount turbo system, and I want this build to be practice/learning to weld.
Owning the rx8 has been one huge learning experience. Three years ago, I barely knew how to do an oil change. By now, I am proud to say that I have either assited or have taken apart almost everything short of parts of the interior and the transmission itself. I think it is time for me to step up my game and enter the fab world.
What I am I thinking
- True 3 inch, single exit, possibly twin, but I have not decided
- One Spiral Style Resonator
- One Muffler
- Bolts up to stock header, 2 or 3 pieces (akin to stock)
Tools I need
- Welder - I know TIG is expensive, and I have been doing some research on it. I would really like your guys opinions in this area. Should I buy new? Used? Supplies I will need as well as running costs ... I am thinking 1 - 1.5k for this
- Pipe Cutter - same as above except for the price range. Where do I even find one?
- Pipe Bender? - I found some pre bent pipe kits online... see below for specific one I am looking at.
Parts I am looking at
- Piping: This (needs to be bent http://www.summitracing.com/parts/SUM-640030/)
OR http://www.summitracing.com/parts/FLO-15902/
- Resonator: http://www.summitracing.com/parts/MOR-94051/
- Muffler: http://www.summitracing.com/parts/SUP-546-3019/
- Header Flange: can you help me locate one?
- Midpipe Flanges:
Can I use ebay for flanges?
I plan on starting this in a month or so.
Last edited by stinksause; 06-07-2012 at 01:38 AM.
.
06-07-2012, 01:36 AM
#9
I would buy a used midpipe and use it for the flanges and the bent pipes...I did that with mine. I cut out the resonators that were in it and replaced them with the new ones...and welded it all together.
You can do a decent job on an exhaust with a MIG....not quite as pretty...but as functional and a lot less work than TIG
You can do a decent job on an exhaust with a MIG....not quite as pretty...but as functional and a lot less work than TIG
06-08-2012, 08:20 AM
#14
read some on exhaust therory. Burns is a good place to start
Applaud you increasing your skills--i haven't learned to weild either. Do it guy.
The hot side of the engine gets complicated with a turbo addition.
I would go with weight reduction--meaning single exhaust. I think I would place the resinator further back on the midpipe.
Learn how to also measure exhaust back pressure--you can defer much work chasing an idea by doing that. Concerntrate on exhaust gas velocity.
Tube headers--flame suit on---IMHO are not good for this engine. We have true zero overlap with the oem ports. A better designed log header would be the best---again imho.
You are dead on with it comes to the collector--that area can use a lot of help!
Applaud you increasing your skills--i haven't learned to weild either. Do it guy.
The hot side of the engine gets complicated with a turbo addition.
I would go with weight reduction--meaning single exhaust. I think I would place the resinator further back on the midpipe.
Learn how to also measure exhaust back pressure--you can defer much work chasing an idea by doing that. Concerntrate on exhaust gas velocity.
Tube headers--flame suit on---IMHO are not good for this engine. We have true zero overlap with the oem ports. A better designed log header would be the best---again imho.
You are dead on with it comes to the collector--that area can use a lot of help!
06-08-2012, 08:51 AM
#15
Clever approach with the Supertrapp, and having the ability to add more plates to the muffler to control the sound somewhat is an added benefit. Aestetically, not sure how it will look on an RX8, but should function well. I totally forgot about those mufflers! It's probably gonna be loud dude so load up on those plates. Burns repacks also would be a good option as dragger stated.
06-08-2012, 09:24 AM
#16
Thanks for the comments, guys.
OD, I have my own ideas about the header that I want to try out, but I do believe that I have cracked it.
I agree that without implementing these, a log header would be best. If I were to build one, mine would be a hybrid, but that is all I am willing to share at this point.
BB rx8, I will look into that stuff in more detail
OD, I have my own ideas about the header that I want to try out, but I do believe that I have cracked it.
I agree that without implementing these, a log header would be best. If I were to build one, mine would be a hybrid, but that is all I am willing to share at this point.
BB rx8, I will look into that stuff in more detail
06-12-2012, 08:41 AM
#24
not qualified to voice an opinion.
have you talked to burns yet? Call them --they can help figure out what pressure waves are happening and how to design the system---megaphone, stepped--whatever. I bet they dont have much experience with zero overlap engines--except a few flathead fords they have probably done.
Have you measure the exhaust system back pressure?
i have been meaning to do that--just havent had the chance.
have you talked to burns yet? Call them --they can help figure out what pressure waves are happening and how to design the system---megaphone, stepped--whatever. I bet they dont have much experience with zero overlap engines--except a few flathead fords they have probably done.
Have you measure the exhaust system back pressure?
i have been meaning to do that--just havent had the chance.