My exhaust project
#1
Teching In
Thread Starter
My exhaust project
I bought some used headers -
What they are new and specs :
http://store.summitracing.com/partde...0&autoview=sku
Here's my improvements :
Loose heat shield- welded up
Welded around the EGR tube better
Welded around each primary on the outside of the flange- I still need to grind some of the welds for bolt clearance.
Grinded the inside for better flow
One of the bungs was stripped on the drivers side collector- re tapped the thread and got nicer plugs. I will use high temp anti seize when I screw them in for good.
Grinded the air tube welds- found out they are brazed on. Can’t weld over that.
The Y pipe collector had some cracks and down the middle you could see light through. I welded up the cracks and I just need to grind out the welds smooth.
Once I finish grinding out the other header on the inside- I’m sending them to Jet hot to get ceramic coated and they will look good as new. Then I go to the exhaust shop and get the mid section on the Y pipe fitted and repaired. I also got new donut gaskets for the Y pipe.
I’m going to have 3” from the Y pipe to the muffler. I have a 3” stainless flex pipe that I’ll install before the high flow stainless cat I just got. Followed by a QTP cutout. I will also will have to weld in an O2 bung after the new cat for the third 02 Sensor.
I still need to buy bolts for everything- the headers, Y pipe and collector. Probably use ARP bolts.
anyway- here's some pics :
http://farm4.static.flickr.com/3065/...8dbb05.jpg?v=0
http://farm3.static.flickr.com/2154/...9f95b4.jpg?v=0
http://farm4.static.flickr.com/3284/...613dfe.jpg?v=0
http://farm4.static.flickr.com/3283/...2ef48c.jpg?v=0
http://farm3.static.flickr.com/2111/...6a1f29.jpg?v=0
http://farm3.static.flickr.com/2146/...baee60.jpg?v=0
http://farm3.static.flickr.com/2210/...34474d.jpg?v=0
http://farm3.static.flickr.com/2055/...77af08.jpg?v=0
http://farm4.static.flickr.com/3128/...333d7c.jpg?v=0
http://farm3.static.flickr.com/2237/...097186.jpg?v=0
http://farm4.static.flickr.com/3143/...c1dd25.jpg?v=0
http://farm4.static.flickr.com/3272/...2c16c7.jpg?v=0
Grinding all done- I also chopped out the Mid section of the Y pipe that was crunched from hitting a speed bump. I also had to retap another bung on the Y pipe- it was crossed a little bit. I'll get the new section welded in when I get the headers on the truck. I'll probably drive my truck open headers to the shop and fit the Y pipe and the rest of the exhaust.
Pics :
[url]http://farm4.static.flickr.com/3062/2427023142_3b3683cf9a.jpg/url]
http://farm3.static.flickr.com/2217/...5c0d194a7e.jpg
http://farm3.static.flickr.com/2180/...ff15116a45.jpg
Got the headers back from Jet-hot. Looks really nice. They did a nice job. They are coated Silver Sterling 1300.
OK, worked a little bit last night. Got the headers installed. The drivers side is a big PITA working around the brake lines. I should have listened to you guys and removed that heat shield. Getting that spark plug in there is a pain. The EGR tube didn't line up well so I'm just going to take it all off and cap it off. I'll leave the air pump lines capped off for now. I used Felpro gaskets and ARP SS bolts.
Pics :
http://farm4.static.flickr.com/3257/...605df1c1_o.jpg
http://farm3.static.flickr.com/2044/...69323f2a_o.jpg
http://farm4.static.flickr.com/3265/...2f1c2035_o.jpg
http://farm4.static.flickr.com/3041/...ba99f906_o.jpg
http://farm4.static.flickr.com/3243/...46483ba2_o.jpg
http://farm4.static.flickr.com/3224/...6e7e5fa6_o.jpg
Stock parts :
http://farm4.static.flickr.com/3261/...e1004e2e_o.jpg
http://farm4.static.flickr.com/3292/...0d586f2e_o.jpg
Got 3 parts Tig welded. This section of the exhaust will bolt inline to the Collector off the Y pipe. It just needs flanges welded on either end now. A Steel Fabricator Company called CT&S in Irving did it for me. I know the owner pretty well and he didn’t charge me to do it. Since the cut out is polished nice, Tig looks better than Mig. His welder, Robert did a good job.
http://farm4.static.flickr.com/3266/...05b89256_b.jpg
http://farm4.static.flickr.com/3097/...f382f7eb_b.jpg
http://farm4.static.flickr.com/3129/...4b1d19bc_b.jpg
I took these pics with my Blackjack II phone. Takes pretty good pics!
Almost done- just need to paint over all the welds with some VHT.
http://farm4.static.flickr.com/3103/...5a9aedc0_o.jpg
http://farm4.static.flickr.com/3292/...33808836_o.jpg
http://farm4.static.flickr.com/3155/...427eb2c0_o.jpg
http://farm4.static.flickr.com/3125/...043a5d08_o.jpg
http://farm4.static.flickr.com/3208/...2fdee765_o.jpg
http://farm4.static.flickr.com/3294/...5e0e73ce_o.jpg
http://farm4.static.flickr.com/3235/...8cca35ed_o.jpg
http://farm4.static.flickr.com/3289/...52fdbf14_o.jpg
http://farm4.static.flickr.com/3255/...76e662d0_o.jpg
http://farm4.static.flickr.com/3292/...cc26f8eb_o.jpg
http://farm4.static.flickr.com/3143/...41116654_o.jpg
http://farm4.static.flickr.com/3081/...c2311b33_o.jpg
What they are new and specs :
http://store.summitracing.com/partde...0&autoview=sku
Here's my improvements :
Loose heat shield- welded up
Welded around the EGR tube better
Welded around each primary on the outside of the flange- I still need to grind some of the welds for bolt clearance.
Grinded the inside for better flow
One of the bungs was stripped on the drivers side collector- re tapped the thread and got nicer plugs. I will use high temp anti seize when I screw them in for good.
Grinded the air tube welds- found out they are brazed on. Can’t weld over that.
The Y pipe collector had some cracks and down the middle you could see light through. I welded up the cracks and I just need to grind out the welds smooth.
Once I finish grinding out the other header on the inside- I’m sending them to Jet hot to get ceramic coated and they will look good as new. Then I go to the exhaust shop and get the mid section on the Y pipe fitted and repaired. I also got new donut gaskets for the Y pipe.
I’m going to have 3” from the Y pipe to the muffler. I have a 3” stainless flex pipe that I’ll install before the high flow stainless cat I just got. Followed by a QTP cutout. I will also will have to weld in an O2 bung after the new cat for the third 02 Sensor.
I still need to buy bolts for everything- the headers, Y pipe and collector. Probably use ARP bolts.
anyway- here's some pics :
http://farm4.static.flickr.com/3065/...8dbb05.jpg?v=0
http://farm3.static.flickr.com/2154/...9f95b4.jpg?v=0
http://farm4.static.flickr.com/3284/...613dfe.jpg?v=0
http://farm4.static.flickr.com/3283/...2ef48c.jpg?v=0
http://farm3.static.flickr.com/2111/...6a1f29.jpg?v=0
http://farm3.static.flickr.com/2146/...baee60.jpg?v=0
http://farm3.static.flickr.com/2210/...34474d.jpg?v=0
http://farm3.static.flickr.com/2055/...77af08.jpg?v=0
http://farm4.static.flickr.com/3128/...333d7c.jpg?v=0
http://farm3.static.flickr.com/2237/...097186.jpg?v=0
http://farm4.static.flickr.com/3143/...c1dd25.jpg?v=0
http://farm4.static.flickr.com/3272/...2c16c7.jpg?v=0
Grinding all done- I also chopped out the Mid section of the Y pipe that was crunched from hitting a speed bump. I also had to retap another bung on the Y pipe- it was crossed a little bit. I'll get the new section welded in when I get the headers on the truck. I'll probably drive my truck open headers to the shop and fit the Y pipe and the rest of the exhaust.
Pics :
[url]http://farm4.static.flickr.com/3062/2427023142_3b3683cf9a.jpg/url]
http://farm3.static.flickr.com/2217/...5c0d194a7e.jpg
http://farm3.static.flickr.com/2180/...ff15116a45.jpg
Got the headers back from Jet-hot. Looks really nice. They did a nice job. They are coated Silver Sterling 1300.
OK, worked a little bit last night. Got the headers installed. The drivers side is a big PITA working around the brake lines. I should have listened to you guys and removed that heat shield. Getting that spark plug in there is a pain. The EGR tube didn't line up well so I'm just going to take it all off and cap it off. I'll leave the air pump lines capped off for now. I used Felpro gaskets and ARP SS bolts.
Pics :
http://farm4.static.flickr.com/3257/...605df1c1_o.jpg
http://farm3.static.flickr.com/2044/...69323f2a_o.jpg
http://farm4.static.flickr.com/3265/...2f1c2035_o.jpg
http://farm4.static.flickr.com/3041/...ba99f906_o.jpg
http://farm4.static.flickr.com/3243/...46483ba2_o.jpg
http://farm4.static.flickr.com/3224/...6e7e5fa6_o.jpg
Stock parts :
http://farm4.static.flickr.com/3261/...e1004e2e_o.jpg
http://farm4.static.flickr.com/3292/...0d586f2e_o.jpg
Got 3 parts Tig welded. This section of the exhaust will bolt inline to the Collector off the Y pipe. It just needs flanges welded on either end now. A Steel Fabricator Company called CT&S in Irving did it for me. I know the owner pretty well and he didn’t charge me to do it. Since the cut out is polished nice, Tig looks better than Mig. His welder, Robert did a good job.
http://farm4.static.flickr.com/3266/...05b89256_b.jpg
http://farm4.static.flickr.com/3097/...f382f7eb_b.jpg
http://farm4.static.flickr.com/3129/...4b1d19bc_b.jpg
I took these pics with my Blackjack II phone. Takes pretty good pics!
Almost done- just need to paint over all the welds with some VHT.
http://farm4.static.flickr.com/3103/...5a9aedc0_o.jpg
http://farm4.static.flickr.com/3292/...33808836_o.jpg
http://farm4.static.flickr.com/3155/...427eb2c0_o.jpg
http://farm4.static.flickr.com/3125/...043a5d08_o.jpg
http://farm4.static.flickr.com/3208/...2fdee765_o.jpg
http://farm4.static.flickr.com/3294/...5e0e73ce_o.jpg
http://farm4.static.flickr.com/3235/...8cca35ed_o.jpg
http://farm4.static.flickr.com/3289/...52fdbf14_o.jpg
http://farm4.static.flickr.com/3255/...76e662d0_o.jpg
http://farm4.static.flickr.com/3292/...cc26f8eb_o.jpg
http://farm4.static.flickr.com/3143/...41116654_o.jpg
http://farm4.static.flickr.com/3081/...c2311b33_o.jpg
#3
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Join Date: Mar 2008
Location: Arlington (DFW), Texas
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Looks good. I need to get my y-pipe built, the 1.75" stocker is terrible.
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Last edited by A Low Dime; 09-02-2011 at 02:19 AM.
#4
Teching In
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#5
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#7
Teching In
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http://farm4.static.flickr.com/3183/...24bafe5a_o.jpg
http://farm4.static.flickr.com/3202/...99c230ea_o.jpg
http://farm4.static.flickr.com/3194/...ef6fa438_o.jpg
http://farm4.static.flickr.com/3191/...9c3bf895_o.jpg
fresh VHT Paint. I used stainless pipe, but used a MIG. So some of the welds were rusting.
http://farm4.static.flickr.com/3202/...99c230ea_o.jpg
http://farm4.static.flickr.com/3194/...ef6fa438_o.jpg
http://farm4.static.flickr.com/3191/...9c3bf895_o.jpg
fresh VHT Paint. I used stainless pipe, but used a MIG. So some of the welds were rusting.
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#8
Teching In
Thread Starter
Worked on the drivers side header again. I was having some leaks. Shoddy braze welds around the Air injection tubes. I had a leak behind the heat shield too. One of the spot welds was loose. While I was at it, cut off the EGR tube. I had it capped off anyway. My steering shaft was melting on the heat shield too. I just removed that orange sleeve. I had the headers Jet hot coated, but messed it up by scratching them removing them again and welding, so I just touched them up with some VHT to hold me out until I can get them recoated. Having the heat shield off also gains better access to the spark plugs. Kinda looks ugly now with all the patches.
http://farm4.static.flickr.com/3123/...11fca31f_o.jpg
http://farm4.static.flickr.com/3287/...1075994b_o.jpg
http://farm4.static.flickr.com/3250/...8729ea6e_o.jpg
http://farm4.static.flickr.com/3170/...32830f7e_o.jpg
http://farm4.static.flickr.com/3035/...ae105c76_o.jpg
http://farm4.static.flickr.com/3225/...e8937a3a_o.jpg
http://farm4.static.flickr.com/3123/...11fca31f_o.jpg
http://farm4.static.flickr.com/3287/...1075994b_o.jpg
http://farm4.static.flickr.com/3250/...8729ea6e_o.jpg
http://farm4.static.flickr.com/3170/...32830f7e_o.jpg
http://farm4.static.flickr.com/3035/...ae105c76_o.jpg
http://farm4.static.flickr.com/3225/...e8937a3a_o.jpg
#9
Teching In
Thread Starter
Ok- New Magnaflow muffler installed. It's a 18" case, 3" inlet, 2.25" dual outlets, polished stainless steel. I know a guy that does exhaust work on the side in his garage and is a magnaflow dealer. I paid $130 for that muffler and he charged me $50 to install it, along with the tips. I chopped off the stainless tips I had on- they cracked and I had to have them reTigged. Then I polished them out to almost a mirror finish. Takes a lot of time to get them that way. I also pushed the tips back so they sit a little farther under the rollpan. I thought they stuck out too much before. I used BBQ 1200 degree paint to cover the welds. Its cheaper than VHT and does the job. I'll try to get a audio clip on how it sounds now. It's a lot quieter at idle vs the flowmaster I had on there. But when you get on it- it has a great tone and no drone. I would highly recommend this muffler for a daily driver.
Pics :
http://farm4.static.flickr.com/3060/...1f1351fa_o.jpg
http://farm4.static.flickr.com/3007/...6c231ee4_o.jpg
http://farm4.static.flickr.com/3244/...b54d9c29_o.jpg
http://farm4.static.flickr.com/3048/...ce1cf446_o.jpg
http://farm4.static.flickr.com/3208/...b52686f2_o.jpg
http://farm4.static.flickr.com/3238/...32af379d_o.jpg
Pics :
http://farm4.static.flickr.com/3060/...1f1351fa_o.jpg
http://farm4.static.flickr.com/3007/...6c231ee4_o.jpg
http://farm4.static.flickr.com/3244/...b54d9c29_o.jpg
http://farm4.static.flickr.com/3048/...ce1cf446_o.jpg
http://farm4.static.flickr.com/3208/...b52686f2_o.jpg
http://farm4.static.flickr.com/3238/...32af379d_o.jpg
#10
Teching In
Thread Starter
I went by Autozone- to see what codes I was throwing. I think my O2s are bad... I started getting the codes after I installed the headers and new Y pipe. The Headers and collectors are Jet Hot Coated. The O2s sensors are still in the same location as the stock Y pipe had them. Attached are the codes. I have an aftermarket tune which deleted the 3rd O2 sensor after the cat. So I have just the main 2 on each side.
If you look hard you can see where the 02s are. Pics :
http://farm4.static.flickr.com/3143/...41116654_o.jpg
http://farm4.static.flickr.com/3255/...76e662d0_o.jpg