peej410 Posted May 14, 2013 Share Posted May 14, 2013 So, in my E36 suspension swap thread I touched upon how my motor made 370 at the wheels. Significantly lower than I was expecting. This was through ebay block hugger headers and a poorly executed (me) dual 2.5" exhaust. Then I got bored around christmas and bought a summer 1-3/4 header build kit, some V-bands and bought a copy of PipeMax software. Here are the subsequent advancements in my Z exhaust. Disappointing dyno pjhptq by peej410, on Flickr Motor. ooo shiny. 76923_10150097380041350_1847848_n by peej410, on Flickr Swageing(SP?) tubes before Header stub shafts. by peej410, on Flickr After Header stub shafts. by peej410, on Flickr Many Header stub shafts. by peej410, on Flickr DIRTY FRAME RAILS MAKE ME ANGRY Header stub shafts. by peej410, on Flickr MMMMM interfacing Untitled by peej410, on Flickr I have since welded a ground lug to the body... Untitled by peej410, on Flickr ugggles Untitled by peej410, on Flickr Megaphones? Untitled by peej410, on Flickr Untitled by peej410, on Flickr Untitled by peej410, on Flickr Untitled by peej410, on Flickr Untitled by peej410, on Flickr Untitled by peej410, on Flickr Embarrassingly enough, I mixed up the center two primaries, (which is what I get for working on it 2hrs at time) and am fixing it tonight) Untitled by peej410, on Flickr And I want to change the 3rd primary in this photo so its not as sharp. Its very hard to build them in the car but no choice really. Untitled by peej410, on Flickr Close up of the secondary collector and megaphone. Some day Ill fix the transition from the secondaries into the collector choke but for now they remain as is. Untitled by peej410, on Flickr Shot of my fugly floors Untitled by peej410, on Flickr The X pipe fits nicely right in front of the diff. its location is not yet fixed. The idea is to make the exhaust behind it parallel so I can slide the X pipe fore and aft to fine tune the position. Untitled by peej410, on Flickr Finally out of the car for modifications and final weld. Untitled by peej410, on Flickr I made the center section near parallel so that If i need extra muffles I can put two offset 3" mufflers in the middle underneath the driver and passenger. Untitled by peej410, on Flickr Money shot Untitled by peej410, on Flickr Mounting will be with these powerflex jobbers http://powerflexusa.com/exhaustmountsexhaustmountsuniversalexhaustmount-exh001.aspx Mufflers I haven't 100% decided on yet This is what you can do with a strong background in fabrication, a new sawzall, good blades, a vise and some various hand held air tools. Criticisms welcome! Quote Link to comment Share on other sites More sharing options...
fastzcars Posted May 14, 2013 Share Posted May 14, 2013 Nicely done! Im in the process of gathering stainless steel supplies for my set! You gave me some ideas!!! Post more pix if you have any more! Quote Link to comment Share on other sites More sharing options...
Leon Posted May 15, 2013 Share Posted May 15, 2013 Sweeeet! I'm in just to hear them! Quote Link to comment Share on other sites More sharing options...
Rob240z Posted May 15, 2013 Share Posted May 15, 2013 I love it. Awesome job. Making my headers in on my bucket list. I'm learning to tig weld currently and it's fun. When I feel like I'm proficient enough I'll tackle something like you're doing. I can't wait to see yours all welded up. Rob Quote Link to comment Share on other sites More sharing options...
peej410 Posted May 17, 2013 Author Share Posted May 17, 2013 There are certain tricks that worked nice. I cut slots into hose clamps through the ribs to position and reposition tubes and be able to tack weld the center through the clamps (start with wide clamps!) Make sure you are well grounded and your tungsten is sharp though. The ark likes to jump to the clamp because of its sharp edge. The other is marking tubes so they are cut square and plumb. I used a combination of painters tape. the clamps and actually found that you can slide a roll of painters tape right over 3" tube allowing you to give a nice round marking line to cut on. I hope to have it making noise by next weekend! Quote Link to comment Share on other sites More sharing options...
fastzcars Posted June 3, 2013 Share Posted June 3, 2013 Hi Peej410, do you have any new progress pix and or video's posted. I'd like to hear how your hedders look and sound? Quote Link to comment Share on other sites More sharing options...
peej410 Posted June 4, 2013 Author Share Posted June 4, 2013 Untitled by peej410, on Flickr Admittedly this is the only update. Tig welding the aluminized header kit just plain sucks. Even grinding it clean inside and out it wont weld clean. Anyways, after coating they will be installed (hopefully this weekend) Quote Link to comment Share on other sites More sharing options...
fastzcars Posted June 6, 2013 Share Posted June 6, 2013 Thanks for posting more pix peej410! it just gives more enthusiasm to continue with my own project! Thanks again. Quote Link to comment Share on other sites More sharing options...
peej410 Posted June 16, 2013 Author Share Posted June 16, 2013 Fathers day update! I lost my pops a few years ago and last night had an odd energy push into the late hours of the night. This was the result http://m.youtube.com/watch?v=-QlYpB2D6HQ Thanks for the nudge pops! I am trying to figure out where to put the mufflers. I may have them come out of each rear quarter like most setups but getting between the tires and the fuel cell will be difficult. I could just dump them in the center and put the mufflers under the tank but it would defeat the whole diffuser plan. Any input? Quote Link to comment Share on other sites More sharing options...
RebekahsZ Posted June 17, 2013 Share Posted June 17, 2013 Input: for my system I have a 2-1 system to a turbo muffler in stock location with improved hangars. I chose my mufflers based on the limited space available and it is fine (not too loud) for the street. I assumed this would be fine for racing too. But, I'm finding more road courses, drag strips and autocross clubs are using sound meters T trackside. They disqualify you and send you home if you are too loud. If I could redo my exhaust I would have a v-band clamp at the end if the stinger where I could clamp on another super quiet muffler for those tracks. Maybe sling it crosswise under the bumper? With the V8 we have plenty power to weight to sacrifice power in order to gain the privilege of driving on these noise-sensitive tracks. I'm traction limited (and sound limited) but not power limited. Quote Link to comment Share on other sites More sharing options...
peej410 Posted June 17, 2013 Author Share Posted June 17, 2013 Well in my car (heavily cut up) if the two mufflers dont cut it, i plan to hog out either floor under driver and passenger respectively to allow for two more mufflers before the X pipe. The problem so far is that the mufflers that are available ruin my total tuned length goal. I need mufflers that the exhaust reacts to like it would straight tube, not an expansion chamber like most good sound attenuating mufflers offer. I really want to cut the floors anyways, but the season is nearing the half way mark and I really would like some track time! Quote Link to comment Share on other sites More sharing options...
Naptown Dave Posted June 18, 2013 Share Posted June 18, 2013 Have you seen the Magnaflow X pipe muffler? I'm kind of interested in it myself. I would think you could add two small mufflers or resonators out back and still have a reasonable volume level. Headers look great! I hope to tackle my own pretty soon. Quote Link to comment Share on other sites More sharing options...
peej410 Posted June 18, 2013 Author Share Posted June 18, 2013 (edited) I have looked at it for sure. Trouble is, I dont know if it would be positive or negative results. This is a good article to read prior to messing with your exhaust systems. http://www.popularhotrodding.com/enginemasters/articles/hardcore/0505em_exh/viewall.html That and a copy of Pipemax software is all I needed to design the system. In a few weeks we will get on the dyno! Edited June 18, 2013 by peej410 Quote Link to comment Share on other sites More sharing options...
Naptown Dave Posted June 18, 2013 Share Posted June 18, 2013 I have looked at it for sure. Trouble is, I dont know if it would be positive or negative results. This is a good article to read prior to messing with your exhaust systems. http://www.popularhotrodding.com/enginemasters/articles/hardcore/0505em_exh/viewall.html That and a copy of Pipemax software is all I needed to design the system. In a few weeks we will get on the dyno! I had to bookmark that article, way too much info for me to digest in one sitting! Thanks! Quote Link to comment Share on other sites More sharing options...
Chris Duncan Posted June 18, 2013 Share Posted June 18, 2013 (edited) Untitled by peej410, on Flickr Tig welding the aluminized header kit just plain sucks. Even grinding it clean inside and out it wont weld clean. Not sure if it would have helped but you might have tried either purging the inside or painting it with Solar Flux. I know it works good on stainless but not sure about mild steel. http://www.solarflux.com/Pages/Productinfo.html with this thin of a weld you are penetrating to the back side and you don't have shielding there, so that may affect the weld. Edited June 18, 2013 by Chris Duncan Quote Link to comment Share on other sites More sharing options...
peej410 Posted June 20, 2013 Author Share Posted June 20, 2013 Chris, The welds on the insides are nice and flat the primaries are 16ga so I wasnt burning through often. I also used .40 filler rod so I wouldnt need too much heat. In the puddle though, you could see contamination (which Immediately thought to back-purge) once it cooled it was obvious it was dissimilar metals you could see a mix of aluminum speckles and mild steel. I tried a lot of options aside from grinding deep into the material there wasnt anything I could do that wasnt going to take minutes per weld joint. Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.