custom exhaust 4 lancer gts

started working on my exhaust last night and today, should have most of it done tommorrow. made out of 2.5" .065" wall 304L ss tubing. i started out by taking off the stock muffler, removing the rubber mounts for use on the new one. i cut the old flange off because its a bullnose flange, not a flat face. i welded the flange to a straight piece of tube to get me by for the night so no fumes would go right into my car. that was last night. today i cut the straight piece off, and made a wye ( Y ) bend. i didnt have a template to cut the tube, so i just made two 45 degree bends, then cut them in half, and welded them together to make a perfect 45 wye. after the wye was done, i welded it to the flange piece. i started making the one pipe, its all ready to go on, but i called it a night. tommorrow i should have the other side done, both welded onto the wye, and the tips nicely beveled. i dont have any rod for hangers, so its just kinda hanging by some stainless wire. ill pick some rod up monday and make hangers.. also NO i didnt back purge, YES I KNOW no need to say anything, and i already know the welds dont look amazing, but they will do for me.

http://i1143.photobucket.com/albums/...t/22b90f57.jpg
http://i1143.photobucket.com/albums/...t/ebea9472.jpg
http://i1143.photobucket.com/albums/...t/b4337a6e.jpg
http://i1143.photobucket.com/albums/...t/5fcc3d49.jpg
http://i1143.photobucket.com/albums/...t/d8651204.jpg
http://i1143.photobucket.com/albums/...t/03bf2460.jpg
http://i1143.photobucket.com/albums/...t/383d47d9.jpg
http://i1143.photobucket.com/albums/...t/24798d24.jpg

J
Nice job
The welds look fine to me. Fit-up on the "Y" must have been a beast.
have you made any mods to the lancer?
What settings have you used?
What does the inside of the tubing look like?
I am thinking of doing or at least trying to do a turbo fold and cold side pipes when we install a larger turbo on our SRT-4 drag car and am trying to decide on steel and jet hot or stainless on the hot side. Id like Aluminum on the cold side

If your going to use stainless on your header area, i suggest using 321L stainless not 304L just because it withstands the heat better and its critical temp it higher.
Fitup for the wye wasent that bad actually, i had center of both 45 pieces and used a straight edge on my bandsaw table. As for mods just an Injen cold air intake. Inside of my tubing sugered but that was expected. I was running around 48-52 with a 3/32 thoriated.

So if you don't purge the tube, is the weld just ugly and looks like sugar on the inside... OR does it affect the weld quality and strength?

Quote:

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Originally Posted by CGCINC

So if you don't purge the tube, is the weld just ugly and looks like sugar on the inside... OR does it affect the weld quality and strength?

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The weld isn't stainless anymore and becomes a weak point. You've got to purge and control the heat.

so i basically finished it all up today. yesturday i made the pipes, cut my bumper, welded the pipes on. today i finished the look by making some "tips" and final positioning. the only thing thats left now, is just to adjust the hangers and bring the exhaust up a little bit more. i ran out of time today, so another day, but that will only take a few minutes of bending the hangers up a tad... so heres some pics....
http://i1143.photobucket.com/albums/...t/274eea03.jpg
http://i1143.photobucket.com/albums/...t/22b4f06f.jpg
http://i1143.photobucket.com/albums/...t/6262ea37.jpg
http://i1143.photobucket.com/albums/...t/6aa915c7.jpg

Nice work, but just one question. Why such sharp bends, wouldn't you get much better flow out of gradual bends?

And how long did the weldor hold onto the bumper before he fell out of his gloves???????