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Old 09-22-2009, 12:52 PM   #26
yama
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Look closely at the picture. Spent yesterday afternoon shifting the fuel tank over to the left ~ 3/4". doesn't seem like much but makes for quite a bit more room on the right side for the 3" pipe. I have 3 seams left to weld but started having gas regulator issues. My tri mix tank went empty so I switched to 75/25 gold gas. It now seems like the regulator died. On hold for now.
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Old 09-22-2009, 01:12 PM   #27
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That stainless exhaust tubing will weld pretty similar to mild steel tubing with that mig.

Back off the wirefeed, perhaps put in a little more heat and just move quickly. You'll never lay down a decent bead with the welder spitting like it is, and I can almost guarantee you'll be back under there fixing all those cold welds soon when they crack.
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Old 09-22-2009, 01:39 PM   #28
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loose the triangles, it will give you a lot more space for the exhaust
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Old 09-23-2009, 12:22 PM   #29
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Finished this morning. Some final pictures. It has a nice low tone and not to loud. The whole setup is pretty stealthy and fits really tight to the body. The flex pipe also seems to have elminated an annoying creak from the rear. All in all I'm pretty happy with it. LH2.4 is still adapting(had battery disconnected) If I did it again I would have purchased more bends so I could avoid miter cuts. I would have also practiced welding stainless more and took more time doing the seams. Ideally I would have liked to TIG'd all the welds instead. I think I would have also purchased vbands with ridges for better interlocking.
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File Type: jpg 3inchdptop.jpg (154.1 KB, 399 views)
File Type: jpg 3inchdpbottom.jpg (199.5 KB, 399 views)
File Type: jpg 3inchota.jpg (147.9 KB, 400 views)
File Type: jpg 3inchside.jpg (74.9 KB, 397 views)
File Type: jpg 3inchrear.jpg (146.4 KB, 403 views)
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Old 09-23-2009, 12:26 PM   #30
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A couple more pictures.
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File Type: jpg 3inchrear1.jpg (140.0 KB, 403 views)
File Type: jpg 3inchfront.jpg (141.6 KB, 388 views)

Last edited by yama; 09-23-2009 at 03:02 PM..
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Old 09-23-2009, 08:31 PM   #31
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How the heck is your car so clean underneath?????? Great job tucking it up, and I just noticed your rear hanger, sweet!
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Old 09-23-2009, 11:11 PM   #32
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Definitely pull the triangle off to get more room...

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Old 09-24-2009, 09:39 AM   #33
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Euro spec never got the triangles.
needs less triangles (someone had to say it)...

nice exhaust. the perfectionist in me doesnt like the welds, but thats just me. welding up a whole exhaust is quite a bit of work if you want to do it right (like here).
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Old 09-29-2009, 07:35 PM   #34
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Its confirmed, I heard this exhaust, went for a ride in the car and the tone is something like that of a very expensive sports car. I was very very impressed
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Old 06-06-2018, 08:56 PM   #35
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Hi nice job . In working on the exhaust .Mine will be 2.5 from a mix of BRZ and volvo XC 90 pipes.
Also I'm finishing my Mazda 6-SaaB,volvo,supra intercooler piping.
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Old 06-06-2018, 09:11 PM   #36
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Very nice exhaust, just curious why you didn't opt for a side exit before the axle?
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Old 06-08-2018, 05:57 PM   #37
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Thread resurrection!
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Old 06-09-2018, 09:39 PM   #38
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Yeah haha...lets see if this guy answers the question...
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Old 06-14-2018, 06:58 AM   #39
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Quote:
Originally Posted by towerymt View Post
Definitely pull the triangle off to get more room...

ive owned 240's since 1996 and ive noticed those triangles.

for the life of me I cannot figure out what they are there for

yes, my pipe is rattling against the triangle on the passenger side

so I can remove that and the car will still run?

thanks in advance
andrew
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Old 06-14-2018, 09:35 AM   #40
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they are there to shear the bolts off the gas tank so ot dropps awy in a rear end collision. the flat.part hits the the rear axel if hit har enugh in the rear
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Old 06-14-2018, 09:55 AM   #41
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I have managed to squeeze a overaxle 2.5" exhaust between the gas tank, overload spring, safety triangle and butt cheek before. Ain't easy or quick. When it rusted out I just bought a stock starla kit...
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Old 06-16-2018, 05:00 PM   #42
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I've done a few 3" exhausts and one 3.5". All over the axle. There is decently space for a 3". 3.5" needs careful positioning, a couple taps to the left front corner of spare wheel well and stiff mounts. And if the car is somewhat low like mine, a couple taps to the pipe over the end of trailing arm so that they won't meet in bigger bumps.

This is 3.5" with the old small muffler.


Had to look up what said triangle is. No wonder I didn't recognize it because there are no such things in Euro-cars.
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Old 06-16-2018, 05:03 PM   #43
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Quote:
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they are there to shear the bolts off the gas tank so ot dropps awy in a rear end collision. the flat.part hits the the rear axel if hit har enugh in the rear
I heard it was to transfer force from a rear end to the suspension.

I didn't have any issue leaving it in with my 3" over axle.
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Old 06-16-2018, 07:24 PM   #44
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The tabs on the 240 rear ate calipers get impacted by the triangles in a large rear impact. The rear of the car above has rear girling calipers which never had the tabs on them or triangles to hit them. The triangles are heavy, too.
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Old Yesterday, 05:14 AM   #45
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Add the support between engine block and header. You will miss it otherwise
no contact in the rear with a really hot exhaust? I can't believe.
I can't believe the share of the bolts too. The triangles will reinforce the rear while involved in a rearendend. A fuel cell that got lost isn't saver as a a deformed fuel cell.
I hate them, heavy and only in "function" with ATE calippers.
Have only seen once at a car imported from the states. A volvo from a diplomate.
good luck, Kay
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Old Today, 12:04 AM   #46
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Interesting timing for a thread revival, doing an over the axle setup on my rally car now, 3''. I've always gone side exit or under axle aside from a SAM 3'' kit I had long ago.

Rally car is a little trickier because of a tank guard that will be in some of the real estate
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Old Today, 07:58 AM   #47
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Quote:
Originally Posted by hessam69 View Post
Very nice exhaust, just curious why you didn't opt for a side exit before the axle?
Probably because that's how children without welding skill would do it, and it sounds awful.
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Old Today, 08:15 AM   #48
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Quote:
Originally Posted by dl242gt View Post
The tabs on the 240 rear ate calipers get impacted by the triangles in a large rear impact. The rear of the car above has rear girling calipers which never had the tabs on them or triangles to hit them.
They come unto play in a hard frontal impact as well by transferring energy through the drive shaft.

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The triangles are heavy, too.
About a pound each if you consider that heavy in a ~ 2800# car.
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Old Today, 09:48 AM   #49
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This thread is almost 10 years old and looks like the pictures were taken with film and then scanned in.
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