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Old 02-24-2015, 11:25 AM   #26
Andrewhans
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It's the little details like the vac hose chaff guard that will help keep this thing reliable. It doesn't take much thinking to keep stuff neat and clean.
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Old 02-24-2015, 11:42 AM   #27
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Thats freaking awesome! for your homemade bead roller on those IC pipes, did you use the "vise grip/exhaust clamp" style bead roller?
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Old 02-24-2015, 11:59 AM   #28
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Originally Posted by cwdodson88 View Post
Thats freaking awesome! for your homemade bead roller on those IC pipes, did you use the "vise grip/exhaust clamp" style bead roller?
Even easier. As long as you don't mind a blister after doing a bunch if pipes. Just get a harbor freight wire crimper, cut the tip off and BAM! Bead roller:

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Old 02-24-2015, 12:10 PM   #29
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Even easier. As long as you don't mind a blister after doing a bunch if pipes. Just get a harbor freight wire crimper, cut the tip off and BAM! Bead roller:

this
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Old 02-24-2015, 03:09 PM   #30
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Had some time to add a few more updates.
I started the down pipe before the engine removal from the beginning but here you go...
I ordered a random set of mandrel bent 3" aluminized steel piping and a 2.5" to 3" small piece and started the mock up. How hard can it be??
After lots of cutting and measuring it came together. Save me some money since this was a budget start.











It fits!!!!

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Old 02-24-2015, 06:28 PM   #31
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Color choice for the bay is perfect. Keep this up!
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Old 02-24-2015, 10:18 PM   #32
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Couple of decent shots:




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Old 02-24-2015, 10:32 PM   #33
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You gotta machine the manifold flat
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Old 02-24-2015, 10:45 PM   #34
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Those pictures are from before engine removal.
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Old 02-24-2015, 11:17 PM   #35
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This is awesome! Great build sir :D
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Old 02-25-2015, 01:31 AM   #36
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Looks killer, love the attention to detail.
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Old 02-25-2015, 09:57 AM   #37
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Quote:
Originally Posted by Lord_Athlon View Post
You gotta machine the manifold flat
Exactly. I figured that one out when it didnt fit flush, but that was a test fit.

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Those pictures are from before engine removal.
Correct. Thank you.

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This is awesome! Great build sir :D
Greatly appreciated.

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Looks killer, love the attention to detail.
Thanks, I can only assume thats the military side in me.




So after reading through Mannes thread I suddenly feel excited and depressed at the same time. Any ways, I guess I will continue posting my inferior work compared to his.

So I did some more work on the Down pipe. In order to make it fit with out the bottom of my pipes dragging the ground, I modified the Transmission brace to allow more space for the 3" pipe. Then Completed the welding to the DP as well as welded on the Wideband and Narrow band bungs:

Pretty rusty in there. Good thing this is temporary until I finish collecting parts for my T5 swap.




For reference of the difference in space created:



Just for extra support (painted it after this):




Down Pipe with flex in it. It would not go on straight so I had to weld it at the angle its at unfortunately but it works:




Painted it with VHT high heat ceramic paint:



Heres a shot for fitment:



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Old 02-27-2015, 06:33 PM   #38
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Wow, no love on my crossmember/ fitment... ok moving on.

While i'm still working on finishing the exhaust, Ill post some pictures of my new coolant tank. I had to make a bracket for it and since im no fabricator, I did the best I could:

Measured and made some bends with a vice:




Cut it so it could have a better shape:




Test fit. Looks ok.



A little paint, and selected place to mount it. I used some window trim weather stripping to isolate the just incase vibration:




Nice and tucked away for a simply clean look:



I recently inquired some SS line for the coolant return so that ugly blue silicone hose is not going on it.



Hope to get some more work done. we will see...



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Old 02-27-2015, 06:37 PM   #39
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Looks great! Good line on the exhaust routing too. I want to see what you do with the t5 x-member.
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Old 02-27-2015, 06:43 PM   #40
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wow man, props to you on the progress and learning. Look forward to seeing more, and I LOVE that color.
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Old 02-27-2015, 08:53 PM   #41
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I'm loving this build. Looking forward to more from you.
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Old 02-28-2015, 12:26 PM   #42
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Quote:
Originally Posted by cwdodson88 View Post
Looks great! Good line on the exhaust routing too. I want to see what you do with the t5 x-member.
Thanks, when I do my T5 crossmember, I feel confident enough to make one completely out of square stock and flat steel like another Tbricker did on here. I am going to redesign it though so that the brace actually goes under the exhaust so that I can tuck it up higher. You will see soon.

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wow man, props to you on the progress and learning. Look forward to seeing more, and I LOVE that color.
Appreciate it brother. The color seems to be a win so I am glad to see everyone likes it. I was actually thinking I would be the only one who liked it, guess I was wrong.

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I'm loving this build. Looking forward to more from you.
Keep browsing. You will see more. Take note too, you will also learn what not to do as well! I learn from trial and error if im trying to do something that I cant seem to find info on.
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Old 02-28-2015, 12:48 PM   #43
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So, I have found building a 3" exhaust is not too difficult for a beginner. The only hard part is the fact that it is 3" and there is no room for an exhaust that size under a 240. Sure you can make the bends and cut and weld to run in the most convenient direction but in the end its still a big a$$ pipe that doesn't belong there. Once again this was a budget build so I used pipes that I had without spending extra money so I did an under axle using what I had on hand. I may go over axle in the future depending on wether this setup works well or not. If its not broke dont fix it right!?

I am still not finished but I have it all tack welded where I want it until I can make some hangars to finalize the location. You may be wondering why its taking a while to build if I said its not too difficult. Well, the lack of spare jackstands and a lift and not mention extra hands makes this job more tedious, but none the less, it can be done by a beginner by himself.

Also, if you ever read this, thanks Mike (Towerymt) for the photos and info you have shared in which I used as a guideline. Without visual aid, this job is kind of challenging.

Well here is what I have so far:

Nice 3" Vband for easy removal..



You may notice about a 2" gap under the driveshaft crossmember. This will be pulled up another inch once the hangars are in place. It should tuck in higher.






Nice Magnaflow exhaust fits perfect under the car without crazy exhaust welds to bring higher or bends. Fits almost completely flat with no worries.





Well I have finished more than that on the exhaust but my phone died before I could take some shots last night, but I will get some shots of the 45* bend coming out around the fuel tank to the rear tonight.

Comments are encouraged both positive and negative please!




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Old 02-28-2015, 12:59 PM   #44
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looks fantastic, ill be keeping an eye here since ill be building another exhaust here shortly. my first attempt... not the greatest lol
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Old 02-28-2015, 01:41 PM   #45
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Quote:
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looks fantastic, ill be keeping an eye here since ill be building another exhaust here shortly. my first attempt... not the greatest lol
Thanks. Im sure in stating this first attempt is not the greatest but definitely a learning experience and save me money for sure.

My grandfather always did everything for himself and he used to always tell me that if someone else can do it, I can too. (now, he never mentioned that it wouldnt be as good as someone else but hey.. perfect practice makes perfect)
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Old 03-01-2015, 06:07 PM   #46
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So I took a few more shots last night.
I was able to make one exhaust hangar using the OG bracket and rubber o-ring.
As of now it hangs at the perfect height but a little to the left. Once I weld the other hangar
it should straighten out. I chose to use the original style mounting instead of rods (what exhaust shops use) to save money even if the rod is only a few bucks.

















As told earlier, her is the 3" coming out the back. I was originally going to run it out the side behind the rear wheel but I changed my mind after looking at it. Looked funky.














Well thats where I am right now. Once I get the other hangar welded, I will fully weld the exhaust and mount it. I have a nice SS tip on order to finish it off. I hope to get that soon so I can be done with it.


until next time..
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Old 03-03-2015, 11:44 AM   #47
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If its not broke dont fix it right!?
NO, if it's not broke, make it faster!

Good work!
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Old 03-03-2015, 03:03 PM   #48
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if its not broke, fix it until it is
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Old 03-03-2015, 04:13 PM   #49
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Good!
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...Ill post some pictures of my new coolant tank. .
The stock cooland tanks always seemed the ugliest part in the whole engine bay,
glad you've made your own.
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Old 03-04-2015, 12:17 PM   #50
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excellent project... just looked through the whole things. It's everything I want and more.
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