Weekend work - Exhaust

[jrtoffroad]

Started building a new exhaust this weekend:


(Cutting angles out of manderal 180 deg bends)


(mock up on the bench)


(old vs. new)


(Positioning and tacking in mufflers)

Sorry for the cell phone pics. Hope to have her fired up this afternoon. Mufflers are 3" in dual 2.5" out magnaflows....just need to find or make some tips (didn't realize my old tips were 2.25"). I'll post a pic of the completed system later.

Anyone else working on their ZR1 this weekend?

-JT

[Aurora40]

3" with an x-pipe, sounds like it's gonna be loud! Looks good, and it looks like you had a Flowmaster system previously?

[Pete]

Very very nice work.
I hate doing/working on exhausts.
Somebody was selling some B&B Tri-flo tips

You might find some extra hp.

Pete

[sammy]

i had built almost the same exhaust but went with the 23/4 in pipe so not to lose too much low end . and went with the dyno max super turbos and adapted the stk zr1 tips to fit . looks great what you are doing .

[todesengel]

Nothing like the thrill of doing things for yourself.

3" may be a bit overkill, and produce a lot more noise, but she sure will breathe good in the higher rpm's!

looks good brother, enjoy!

[jrtoffroad]

Ended up being able to modify the magnaflow tips that were on the old exhaust:


(cut tips were inside diameter equaled 2.5", then add new extensions)


(Shown here with 2.5" extension, no restriction in flow)


(Everything tacked in place)




(Finish welded & painted, ready for final install)


(Another angle)

Just got back from a drive. Definitely louder, but really not too bad at cruise. Sounds down right mean above about 3k rpm, very unique. The flowmaster system had a very nice v8 rumble, but, in my opinion, this is the sound a hot LT5 deserves. Hope to get it on the dyno soon.

[jrtoffroad]

Thanks for the comments. No question, a 3" system is probably a little over kill for stock displacement, but figured if I'm going to build it, why not go all out? Low end feels about the same, but does seem to pull a little better at the top end. Need to get it on the dyno to really see if I gained anything.

One thing that shocked me was how much lighter this new system is than the flowmaster. Must be at least a 20lb weight savings.

[todesengel]

Originally Posted by jrtoffroad

Thanks for the comments. No question, a 3" system is probably a little over kill for stock displacement, but figured if I'm going to build it, why not go all out? Low end feels about the same, but does seem to pull a little better at the top end. Need to get it on the dyno to really see if I gained anything.

One thing that shocked me was how much lighter this new system is than the flowmaster. Must be at least a 20lb weight savings.

Never a knock, just my worthless $.02. It always does my heart good to see people doing their own thing. If you are happy with it then it is the perfect system.

I am not a very big fan of thin walled tubing for exhaust as it seems to give a bit of a "tin" sound. Post a video up, I would love to hear it if you do not mind!

[jrtoffroad]

Originally Posted by todesengel

...I am not a very big fan of thin walled tubing for exhaust as it seems to give a bit of a "tin" sound. Post a video up, I would love to hear it if you do not mind!

I used 16ga tubing, which is pretty standard. I thought about using some 18ga, but since my car is lowered the exhaust is a little vulnerable and I'd hate to crush it on a speed bump. I think the weight savings mainly has to do with the mufflers. Those flowmasters are made out of some thick stuff.

I'll try and get a video posted in the next couple days.

[sammy]

my white car is lowered almost 2 in. i have been thinking of trying that oval tubing that they use in nascar to create a little more space between the exhaust and the ground . got to look into the price of doing such a system . very nice what you did and adapting the tipps a nice touch too .