New Exhaust Build
 

Out with the Old:

http://i93.photobucket.com/albums/l5...ustOnFloor.jpg

http://i93.photobucket.com/albums/l5...Completed3.jpg

In with the new:
Well I sold my 3" true dual exhaust to build a new setup. The goal of the new setup is to be quieter and lighter. I decided to go with 3" to a Y, and then 3.5" from there back. I also needed to use a lot more muffler than previous. I couldn't find any mufflers in the size I wanted, so I decided to make them myself.

The design of the mufflers is a 4 piece, repackable design. There are two endcaps, a floating perforated tube core, and an outer casing. The outer casting is aluminum to keep it lightweight. I also put V-band flanges on both ends of the mufflers to make it easy to remove, repack, and reinstall. The first muffler will be a 5" case, the second an 8" case.

Raw materials. Only part still missing is the sound absorbing mat.
http://i93.photobucket.com/albums/l5...ustParts-1.jpg

Started on the Y part, with a V-band right on it. That is where the first muffler will go. Needed a helping hand so I quit with this, and started on something else.
http://i93.photobucket.com/albums/l5...1Progress4.jpg

Muffler endcaps. The endcaps are as short as possible to make it possible to fit as much muffler as possible. The endcaps extend into the muffler 1". This is so the perforated tube will slip over it and float inside the muffler. I had the perforated tube made to my specs. 3/32" hole size, 3/16" spacing, staggered, 16 ga, 304SS, 3.530" ID.

This is the 5" case muffler.
http://i93.photobucket.com/albums/l5...1Progress5.jpg

Closeup of the V-band endcap.
http://i93.photobucket.com/albums/l5...1Progress6.jpg

Then the endcap for the larger muffler.
http://i93.photobucket.com/albums/l5...1Progress3.jpg

http://i93.photobucket.com/albums/l5...1Progress2.jpg

http://i93.photobucket.com/albums/l5...1Progress1.jpg

The other end of the large muffler will have some sort of exhaust tip on it, probably just a piece angled down to point the exhaust down slightly (to help with my dB readings).

The muffler is too long in this pic, I still have to cut it down to size. I'll probalby take ~4" off of it and have it be a 20" case muffler.
https://i93.photobucket.com/albums/l...hasutYpipe.jpg

More in the next few days as I progress.

Noticed this got moved. This has little do to with my engine choice, but a lot to do with fabricating an exhaust from scratch.

Pretty much finished up now. All that is left to do is pack the mufflers and replace the aluminum rivets with stainless steel ones. Oh yeah, and clean up the aluminum muffler cases.

The front muffler ended up being 22" long, and the rear muffler 18" long. All in all 11 lbs lighter than my old setup. Not quite the weight savings I was looking for, but I guess its because I have such huge mufflers.

http://i93.photobucket.com/albums/l5...Completed1.jpg

http://i93.photobucket.com/albums/l5...Completed2.jpg

http://i93.photobucket.com/albums/l5...Completed4.jpg

http://i93.photobucket.com/albums/l5...Completed5.jpg

The money shot. Gotta keep the visible welds looking top notch.
http://i93.photobucket.com/albums/l5...Completed3.jpg

wow those welds are truely top notch for sure very impressive!

I did some re-arranging of my photobucket and need to edit my posts to reflect the correct links, but cannot edit my post. Damn the restrictions on this forum are annoying. Some good info here, but extremely not user friendly.

Here are the pics again.

http://i93.photobucket.com/albums/l5...haustParts.jpg

http://i93.photobucket.com/albums/l5...1Progress2.jpg

http://i93.photobucket.com/albums/l5...1Progress1.jpg

http://i93.photobucket.com/albums/l5...1Progress3.jpg

http://i93.photobucket.com/albums/l5...1Progress6.jpg

http://i93.photobucket.com/albums/l5...1Progress5.jpg

http://i93.photobucket.com/albums/l5...hasutYpipe.jpg

http://i93.photobucket.com/albums/l5...Completed1.jpg

http://i93.photobucket.com/albums/l5...Completed2.jpg

http://i93.photobucket.com/albums/l5...Completed4.jpg

http://i93.photobucket.com/albums/l5...Completed5.jpg

http://i93.photobucket.com/albums/l5...Completed3.jpg

http://i93.photobucket.com/albums/l5...ngMuffler2.jpg

http://i93.photobucket.com/albums/l5...ngMuffler1.jpg

http://i93.photobucket.com/albums/l5...pletedTip1.jpg

http://i93.photobucket.com/albums/l5...pletedTip2.jpg

http://i93.photobucket.com/albums/l5...pletedTip3.jpg

http://i93.photobucket.com/albums/l5...pletedTip4.jpg

Amazing work as always.

And the video. I had to take my son with me so he didn't get a blast of exhaust in the face or knock down my DSLR. Not sure what the smoke was all about, I've never noticed it before, so I'm thinking its all the oils burning off the inside of the new tubes. Its considerably quieter than before. Not quiet by any means, but a huge improvement. Have yet to drive it anywhere, still a few odds and ends to tie up.

http://www.youtube.com/watch?v=Y5Y1-vPXFUw

An update after several months installed. I am still in awe of how quiet the car is inside now, I can actually hold a conversation while driving. I'd highly recommend a setup similar to this if you're having excessive cabin reverberations from the exhaust.

No issues with the aluminum cases either, after several autoxs, and even an FTD thrown in there.

Very nice dude, nice noise and saved some wieght too i would suspect

Quality exhaust! Looks and sounds fantastic. And appears to be about half the weight

It was minus 11 lbs so a nice savings there. And it gained some VE on the retune so a gain all around.

Very clean! I like it.