Building an exhaust

[jim]

Despite the fact I have electrical faults throughout the cortina I have decided to make an exhaust because when it does run it's rather loud!

Problem is I've never made one before - I have done a bit of research into what components I'll need but I cold do with some more advice

Joints - I wasn't going to use flexible ones but wasn't sure whether to us V bands as much as I need to, the manifold is 1.5 at the end with a 60s style v band which i was going to remove and fit a 1.5 to 1.75 reducer - upping it to the right size from the manifold out then using a sleeve to go over that for the main straight and secure with a U bolt

www.ebay.co.uk/itm/1-75-V-Band-Turbo-Clamp-CNC-Stainless-Steel-SS304-Flange-Kit-/221915051830?hash=item33ab2af736:g:PdUAAOSwVL1WCP29

Hangers - modern rubber types, shouldn't be an issue

Over axle - Jetex off the shelf affair

www.ebay.co.uk/itm/Jetex-Universal-Exhaust-Over-Axle-Bend-1-75-Stainless-Steel-/290617282192?hash=item43aa23ce90:g:pdIAAOSwNphWXfjc

Silencer - I want the cortina to have a nice raspy noise but nothing too loud so I have a few ideas

www.ebay.co.uk/itm/UNIVERSAL-STAINLESS-STEEL-EXHAUST-SILENCER-1-75-BORE-8-x-5-SECTION-x-12-LONG-/370539204477?hash=item5645db8f7d:m:mKGWMzGSgNI_dvNIEwp0T5w

this will need a tail pipe fabricating but would give the quietness I'm after.

www.ebay.co.uk/itm/Universal-Stainless-Steel-Exhaust-Bomb-Silencer-Tail-Pipe-Back-Box-/271524704833?var=&hash=item3f38223241:m:mj__24FKMu5rM4r0WL045oA

I'm not sure how this would sound but its straight through which is good for performance, I have a feeling that I'll need to cut the tailpipe and add a small bend in so that it exits the rear straight but thats just a personal thing!

[skylinedave]

You can make hangers put of stainless bar where you need them and weld them . How are you going to sleeve it together ? Buy flared sections and weld them on ? Or buy a flaring tool ? I don't jnow how they cope with stainless ? Got a tig welder or mig ?

[drake1994]

try a company called clamp co, also not you can get 16guage bends reasonable cheap, i made one for the avenger 2" straight through, yer its abit rawty but its a nice rawty, i use exhaust clamps that a mk2 golf gti would use, basically a slotted tube with a clap either end, all you do is slot both side in and tighten up

[jim]

That'll make things easier if I can make my own hangers! The flares would be off the shelf I'll need 1 for the manifold to pipe, the over axle has one as it comes leaving at least one v band.

Welding will be mig tack welds to hold it followed by full tigs once it is all done

[drake1994]

thats how i do it usually, sounds like you have it pretty much sussed, just take you time and get it hanging right, nothing worse than doing it twice after you find it braying off the shell like mine currently is

[skylinedave]

Yes sound like you have it sussed , make sure you cut pipes completely square across at 90 degress to the side , Any small deviation and it will most likely pull over , meaning you pipe is going a degress or two out ! Learnt that the hard way as a apprentice !!

Back purge it if possible [ fill will another source of argon from a t piece if you can when welding it , it will make all the diifrence inside the pipe . You can use a t piece of the one gas bottle if you have a flow meter to make sure you are running enough gas for the welder .


Does sound like you have worked out a good stratagy though , best of luck with it .

[elmotheewokking]

I doubt you would, but don't even attempt to use the cheap pipe expanders for stainless. When trying to flare my 2" tube for my side exit, they were utterly useless.

[skylinedave]

Yes beter of just buying and having a extra weld . When i used to make them we used this www.avamatic.co.uk/av65s.html . A great piece of machinery .