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post #1 of 16 (permalink) Old 03-13-2006, 06:54 PM Thread Starter
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Just installed true-dual exhaust

I had a free weekend, and everything I needed, so I spent about 12 hours yesterday cutting mandrel bends, tac welding, and getting under and out from under my an car innumerable amount of times. The result was a 2.5" true dual exhaust, cats, magnaflow x-pipe/resonator, and 2 Borla XS mufflers.


It actually isnt any louder than my stock exhaust without the rear mufflers, and is perhaps quiter inside the car. It has a slightly different tone though. I like it.


The SOTP meter isnt telling my much of anything as far as power gains, however it seemed to pull a little better on the Interstate today.

... as this was my first endeavor into fabricating exhaust systems, this one seems to hang a little low in the rear... I'll have to watch those speed bumps until I get a chance to get back under there and fix that

math > pasta
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post #2 of 16 (permalink) Old 03-14-2006, 12:16 PM
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How much $

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post #3 of 16 (permalink) Old 03-14-2006, 12:31 PM
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Pics please.


1997 Thunderbird Sport
Low Miles
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destined to remain stock

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True Dual exhaust with Magnaflow DI/DO muffler
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post #4 of 16 (permalink) Old 03-14-2006, 12:33 PM
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Your car originally had a third cat, right? You think you will have trouble passing emission testing? I want to get done what you did, high flow cats, no third cat, x pipe, two small round mufflers mid mounted, 2 1/4 pipe all the way back.

Plus finding someone that will get rid of the third cat is not likely, I have called a couple of places, and they seem to only do after that third cat. I don't want it to fail the visual inspection. My mufflers are pretty crappy right now, the inner muffler has leaks and a ton of stuff is dumping out the drain hole.

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post #5 of 16 (permalink) Old 03-14-2006, 12:55 PM Thread Starter
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Quote:
Originally Posted by Midnight
How much $

I think I have about $350 or so invested. I got the X-pipe/res for x-mas, so add a little more for that.


Quote:
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Pics please.
I have a couple on the camera, I'll get 'em off as soon as I can.

math > pasta
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post #6 of 16 (permalink) Old 03-14-2006, 12:56 PM Thread Starter
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Quote:
Originally Posted by Bangster
Your car originally had a third cat, right? You think you will have trouble passing emission testing? I want to get done what you did, high flow cats, no third cat, x pipe, two small round mufflers mid mounted, 2 1/4 pipe all the way back.

Plus finding someone that will get rid of the third cat is not likely, I have called a couple of places, and they seem to only do after that third cat. I don't want it to fail the visual inspection. My mufflers are pretty crappy right now, the inner muffler has leaks and a ton of stuff is dumping out the drain hole.

well, I guess I'll find out about the emissions this fall I think I'll be alright though.

math > pasta
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post #7 of 16 (permalink) Old 03-14-2006, 08:14 PM
 
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I'd love to do that with my car this summer... where did you get the mandrel bent pieces, and what shapes would you recommend? spintech baby
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post #8 of 16 (permalink) Old 03-28-2006, 02:05 AM Thread Starter
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I got the mandrel pieces from summit. I got 180* J-bends. If I had just ordered a bunch of 45* bends, I think I might have had less trouble, but that would have cost me about 4 times as much (since the 45* and 180* pieces I was looking at were about the same price.



pics!!


Heres the completed front section. I was in a hurry, so I lopped off the upper portion of the stock downpipes,welded in an adapte, and built from there. That will be replaced with 2.5" next time I get under the car... probably this summer.



another shot of the front section. Frank couldnt resist shocking TCCoA



one of many trips to the bandsaw



midway through the rear section. We had been at it for a good 10 hours at this point, and were pretty tired. So we got a little rushed and sloppy. This is where our angles really started to stray



back at the bandsaw... only about half as dirty as I was when we finished.




a shot of the rear section in the car




A shot from the rear.... you can really see how low it is in this one. Next time I get a few days to myself, I'll fix the geometry on a few spots so it'll tuck up higher. For now, I'll just take it slow over the speedbumps.

math > pasta
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post #9 of 16 (permalink) Old 03-28-2006, 10:33 AM
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looking good, nigel. how low does that magnaflow hang down?

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post #10 of 16 (permalink) Old 03-28-2006, 03:33 PM Thread Starter
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Thanks mike, the Magnaflow isnt too bad (though it could stand to be a little higher). I just need to take a weekend and rework a couple of the angles, and it should be fine.

math > pasta
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post #11 of 16 (permalink) Old 03-29-2006, 07:37 PM
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Nice work. The only suggustion I would make is put a connection somewhere so if you have to do rear work or header work you can take just half the system down instead of all of it. Ball connections work well, that way you can adjust the pipe alignment some for a better fit. Also double check all the welds to make sure there are no leaks at all.
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post #12 of 16 (permalink) Old 03-29-2006, 08:28 PM Thread Starter
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Quote:
Originally Posted by Hollywood Ed
Nice work. The only suggustion I would make is put a connection somewhere so if you have to do rear work or header work you can take just half the system down instead of all of it. Ball connections work well, that way you can adjust the pipe alignment some for a better fit. Also double check all the welds to make sure there are no leaks at all.

I ordered some ball connections, but they didnt show up in time for the install.... in fact, they never showed up. I was only able to find one place that carried them (Dr. Gas). Summit has some, but they are 3" in and 2.5" out (or vice versa)... any idea where else I could nab some? Right now I have some exhaust clamps at the back end of the magnaflow, but I'd much rather the ball connectors.

We pressure checked 99% of the welds before we installed them (ie, Frank held his hand over one end, I stuck my face over the other and blew. Listened for leaks and watched for weld smoke coming out). We were satisfied. When I get under there again, any leaks we missed should be pretty apparent.

math > pasta
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post #13 of 16 (permalink) Old 04-11-2006, 06:16 PM
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nice setup, and i love the homemade leak checker
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post #14 of 16 (permalink) Old 04-11-2006, 06:25 PM Thread Starter
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Quote:
Originally Posted by Lithsanatrex
nice setup, and i love the homemade leak checker

thanks


I'm going to Switzerland for 10 months or so starting in October, so now I'm thinking about selling it this summer. Need to finish up the brake upgrade and hub swap first though, and some general tune-up stuff. Almost a little frustrating, getting all this work done on it, and now I'm possibly going to sell it.


Anyone interested in a hard-run '92 LX?

math > pasta
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post #15 of 16 (permalink) Old 04-13-2006, 08:46 AM
 
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Nice. I can't believe you don't feel much difference. My sotp meter showed huge gains from new exhaust. 1/4 mile times showed 20hp gain I installed 1 5/8 shorty headers at the same time though. The factory rear mufflers were in place before the swap also.

The mandrel bends are nice. Mine has a few spots where the compression bends are probably hurting flow. Oh well, a stick of pipe costs the same as 1 mandrel bend probably.

I took the ball connection from the Mustang h-pipe I ordered and totally hacked up. Most muffler shops can make a ball connection or have used ones around. You could also get them from a salvage yard.
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post #16 of 16 (permalink) Old 04-13-2006, 10:49 AM
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