View Full Version : 304 SS exhaust system

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...

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.

It's tight.

I just love welding SS, I know I can always improve though.

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.

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.



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.

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.

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

Seal of approval. :D

Might not look like much, but the bracket was cut on the CNC table. Quicker and easier than doing it by hand.

05-28-2012, 09:39 PM
Lightly polished SS tip welded onto the muffler

All done!

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

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?

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.

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

1 down 1 to go, polishing up the old tips.

Got my backpurge setup running, one flow meter (grey hose) is for the TIG the other (green hose) is for backpurging prior to welding.

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".

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.

All done.

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

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

Or do you mean the second car?

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

Looks to be a FWD sedan?

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.

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.

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:

All done!