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I got out my grinder and attacked a short length of spare exhaust pipe thismorning.

This is what i have come up with so far

There appears to be heaps more room in the up-pipe. Much better flow.
That and a TF035 should be sweet.

Now i just have to weld it.

Should i stengthen the bends on the outside somehow?

ooo looks the goods. looks like a cheap way to do it too

looks like a good little upgrade. interesting to see how it goes. go easy on the welds and be sure to try and get like a wire brush in there and get all the ruff bits out.

looks good, you can start making mine when your done with that one

looks very good nice work m8 so when r u taking orders? lol

good stuff...should make a reasonable difference..i got a similar issue with my rex i think i mentioned before...not the up pipe but the pipe from the 1 head to the other has a very very crappy piece in it im thinking of removing and doing the same as yourself...would love to see and head about the finished product before i start butchering

dave

Ok, ran into an issue

Because there are slithers of metal only 5mm wide, when i try to weld them together, they melt (there is nowhere for the heat to dissipate) even on the lowest setting on the mig.

Im gonna have to go to the exhaust shop and get some crush bend bits made up.

Try turning the heat and feed up, you might be surprised...

Yeh increase the rate of feed and see what happens. Also try clamping a sheet of copper to the back of the weld, should act as a heatsink but wont tack to the weld (well it shouldn't...).

i've always done exhaust welding with the mig set at about 4 out of 6. 180 amp welder.

I also noticed the disc you were using was not a thin cutting disc. might have payed to use one of the fine cutting discs on the grinder so u weren’t removing so much metal.

The disc i bought was the thinnest they had.

Even if i do get the welds right, i still feel they are gonna be a weakness because of the repeated heating/cooling of the exhaust

yeh might just pay to get a zorst shop to bust the bends for you. i couldnt see it costing much. 6pac even? :P

Suparoo wrote:Even if i do get the welds right, i still feel they are gonna be a weakness because of the repeated heating/cooling of the exhaust

But the exhaust isn't a load bearing member is it? I think it wouldn't make a difference how strong it is? (Not that it would be weak anyway)

I think if you wanted to leave the horrible "T" junction there the go may be to make a flange plate and weld it to the side of the T . That way its easy to get a section of press bent or mandrel bent tube/pipe , fit flanges either end of the now removable up pipe and bolt it on .

For the bit of extra work involved I still think making a proper collector with its outlet facing the up pipe (turbo) the gains would be worth it .
Make no mistake , the std header is absolute garbage .

Cheers A .

removable up-pipe, i like it.

Im gonna leave the t piece there, mainly because i dont have the resources to do it any other way. Im making the t piece deeper so it flows better.

I havent even had a chance to go back to the exhaust shop this week, been flat out.

I suppose if you could get the turbo end pipe to join the collector a little more from underneath it may get a bit more exhaust energy from the offside head . Major problems in the std header - obviously they didn't want much performance from it .

Cheers A .