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Conrad_Turbo
05-16-2012, 07:32 PM
Well since I don't have a Celica anymore and I primarily do work for my customers, this is what I'm working on right now. :D

Removed the front pipe and mid pipe, beginning the 3" front pipe section...
http://www.aceengineering.ca/Temp/40D/IMG_0950.jpg

Coping with the plasma cutter and a template. I find running low amperage with a 45A nozzle yields less cleanup on the inside of the tube. I'm sure it'd be even easier if I had some anti-spatter spray as well.
http://www.aceengineering.ca/Temp/40D/IMG_0940.jpg

It's tight.
http://www.aceengineering.ca/Temp/40D/IMG_0941.jpg

I just love welding SS, I know I can always improve though.
http://www.aceengineering.ca/Temp/40D/IMG_0997.jpg
http://www.aceengineering.ca/Temp/40D/IMG_0999.jpg

Rough mock up. There will be a v-band in the long straight section to break up the front pipe from the mid pipe. Twin 3" merging into 4" all the way to the back.
http://www.aceengineering.ca/Temp/40D/IMG_1010.jpg
http://www.aceengineering.ca/Temp/40D/IMG_1016.jpg

Should be putting down 550awhp when the owner is done with it, it's an R32 Skyline. I didn't do any real engineering CFD with this exhaust system however this car is an engineer that works for me and he did all the CFD/flow calculations and had very specific constraints on how he wanted it built. Not too many of my customers are as particular as him!

Should be cutting some custom hangers for it as well, the beginning of this year I set up and am now running a CNC plasma/engraving table. 4'x4' capacity and can cut up to 1" thick steel.

http://www.aceengineering.ca/Temp/40D/CNC/IMG_8321.jpg

:D

KoreanJoey
05-16-2012, 09:15 PM
Beautiful man, really. I wish I had access to a TIG welder. I've always been really impressed with what a skilled TIG welder is able to do. Art in functioning metal is something I can always appreciate.

Conrad_Turbo
05-17-2012, 05:20 PM
To be honest I wish I did a lot more TIG welding, but I'm also stretched thin doing 3D modeling, FEA, running the plasma table, polishing, invoicing...blah blah blah. It's tough to be really good at one craft when you're doing so many things.

TIG used to be super stressful due to the multitasking that goes on, using 3 limbs to lay a nice bead, stressful enough that I had to chew gum to keep me from clenching my teeth! But now that I've done it for a few years it's super relaxing and I find it helps me to unwind. I'm by no means a pro...but I have yet to have a part come back because of a failed weld. TIG welding is just relaxing and it's fun making pieces of metal into a functioning part or art...or both!

I got quite a bit more done last night, I'll post up more pics once I get more progress shots.

Conrad_Turbo
05-28-2012, 09:38 PM
All bolted up and ready to go!

Seal of approval. :D
http://www.aceengineering.ca/Temp/40D/IMG_1763.jpg
http://www.aceengineering.ca/Temp/40D/IMG_1771.jpg
http://www.aceengineering.ca/Temp/40D/IMG_1773.jpg
http://www.aceengineering.ca/Temp/40D/IMG_1779.jpg
http://www.aceengineering.ca/Temp/40D/IMG_1784.jpg

Might not look like much, but the bracket was cut on the CNC table. Quicker and easier than doing it by hand.
http://www.aceengineering.ca/Temp/40D/IMG_1787.jpg

Conrad_Turbo
05-28-2012, 09:39 PM
Lightly polished SS tip welded onto the muffler
http://www.aceengineering.ca/Temp/40D/IMG_1792.jpg

All done!
http://www.aceengineering.ca/Temp/40D/IMG_1812.jpg
http://www.aceengineering.ca/Temp/40D/IMG_1843.jpg
http://www.aceengineering.ca/Temp/40D/IMG_1850.jpg
http://www.aceengineering.ca/Temp/40D/IMG_1859.jpg

underscore
05-28-2012, 10:30 PM
that is BEAUTIFUL. Any sound clips yet?

Conrad_Turbo
05-28-2012, 10:52 PM
Nope no vids yet as the car won't be running for a little while. The car has a spare head on it for mock up purposes, the real one is getting some aggressive work done to it along with a lot of other work being done to the engine. Not sure when he's going to get the car buttoned up and running.

joe's gt
05-29-2012, 04:50 AM
CLEAN!!! I assume you did not have access to a mandrel bender hence the multiple weld sections to achieve the desired bend radii?

Conrad_Turbo
05-29-2012, 05:46 AM
I could use a 4" mandrel bend to cut and weld in, the customer wanted it to be pie cut, so I did that with small bends to keep the flow smooth. Takes way more time to fabricate, but looks awesome and allows for more control since I can jog the bend in multiple directions along the overall bend.

Conrad_Turbo
07-27-2012, 05:15 PM
Knocked out another one.

1 down 1 to go, polishing up the old tips.
http://www.aceengineering.ca/Temp/40D/IMG_4474.JPG

Got my backpurge setup running, one flow meter (grey hose) is for the TIG the other (green hose) is for backpurging prior to welding.
http://www.aceengineering.ca/Temp/40D/IMG_5064.JPG

Backpurge jig that I knocked off the CNC table. It allows me to just bolt it up to begin backpurging 2.5" exhaust systems, or at least systems with the same width bolt pattern. Backpurging protects the backside of the weld while welding. I'll be cutting a set of flanges to allow me to backpurge from 2" up to 4".
http://www.aceengineering.ca/Temp/40D/IMG_5053.JPG

The old hangers were not the best, ended up ripping them off the car...so I made new ones that were welded to the car. 1/2" 304SS rod welded to a steel plate with 309 filler.
http://www.aceengineering.ca/Temp/40D/IMG_5065.JPG

All done.
http://www.aceengineering.ca/Temp/40D/IMG_5070.JPG
http://www.aceengineering.ca/Temp/40D/IMG_5075.JPG
http://www.aceengineering.ca/Temp/40D/IMG_5096.JPG
http://www.aceengineering.ca/Temp/40D/IMG_5080.JPG

underscore
07-27-2012, 05:36 PM
What car is that for?

l0ch0w
07-29-2012, 11:25 PM
R32 Skyline...

Or do you mean the second car?

underscore
07-30-2012, 12:49 AM
Second car.

Looks to be a FWD sedan?

Conrad_Turbo
07-30-2012, 06:46 PM
The second car is an early 90's Pontiac Sunbird with a swapped engine in it IIRC. The owner seen the work I've done for other customers and just wanted to have the same for his car.

Conrad_Turbo
08-07-2012, 05:51 PM
More stainless... This time I got the pieces shipped to me with alignment marks, I had to align everything and keep it straight prior to welding.

Keeping everything nice and straight.
http://www.aceengineering.ca/Temp/40D/IMG_5152.jpg

Ready for welding. Kapton tape is the bees knees, it leaves no residue when removed, can withstand 400deg C and makes anything stainless look like something from NASA. :giggle:
http://www.aceengineering.ca/Temp/40D/IMG_5154.jpg
http://www.aceengineering.ca/Temp/40D/IMG_5160.jpg

All done!
http://www.aceengineering.ca/Temp/40D/IMG_5166.jpg
http://www.aceengineering.ca/Temp/40D/IMG_5169.jpg