slate blue

Guys here are a few pics of my exhaust, it has taken forever to build, forever is 3 months full time BTW. The reason it took so long was multiple, but I did build almost everything myself, bar the Burns mufflers and collectors. Also all the welds in the system after the headers were ground internally, very very time comsuming. All welds were back purged too, this makes a huge difference, without this I would say it is pointless to try and build a really good system. Also working on the ground slows you down along with the fact, 3'' is very hard to fit to a S2 while maintaining excellent ground clearance.

My car with one man power.



My girly assistant.



The headers after coating





This photos shows what I did with welds internally, it has all been smoothed out.



This is a gutted GT muffler, it has been fitted with 3'' pipe that I made like the Burn's units are, the perforated core is a fine lightweight mesh, these mufflers weigh 2.5 kgs each. The Burns units weigh 1 kg each.




I also packed the mufflers with some new fibreglass and wrapped the perforated core with the stainless wool, you do this to protect the fibreglass from the heat.


My home made X-Pipe



The variable backpressure valve



The whole system including the headers weighs 30 kgs, if I didn't try to save weight a 3'' system would have ended up weighing a portly 65 kgs.

What does it sound like, well in 2 weeks I will know. I suspious that it will be too loud, time will tell.

Cheers Greg

drnick

greg, that is simply beautiful! the whole system, and the headers... i really want some!! too bad ive gone to 32v... whats your reasoning on dual 3" i thought 2.5" inch dual was sufficient? im thinking my next system would be a single pipe with a Y collector. awesome work, i bet you cant wait to hear it let alone drive it!!

AO

More shots of the "girly assistant" please!

(BTW, exhaust looks good too! )

SwayBar

Your exhaust looks as good as Carl's newly built engine; nice work!

I hope you are pleased with it's resulting sound.

slate blue

Hi Dr Nick, well 2.5" is enough generally but when you're going to have 5.8 Liters and then 6.6 liters you need more, I don't have time to build another system and I could never afford to pay somebody to build such a system. I will change the X to 3" when I go to 6.6. At present the X is 2.5". The rest is 3".

What my idea is, and we'll soon find out, the dyno tells no lies! is that after the X it doesn't matter so much, I mean good velocities through the X and then you want low backpressure. My system allows just one pipe to operate unless you need full flow of the exhaust. This means good velocities with low back pressure. Back pressure is a big power robber.

Nothing in my opinion wrong with you idea either, you could certainly make it light. If my system was a single 3" it would only weigh 20 kgs and that includes the headers.

Good luck.

Greg

Carl Fausett

I'd be proud to call that mine. Well done. Grinding the wleds on the INSIDE to that degree of smoothness takes forever - good job!

Normy

What's the theory and practice about the "variable backpressure valve"?

N?

marton

great fotos & great work

Marton

SMTCapeCod

The valve is interesting. My VR4 had one that was electrically activitated, triggerred by the ECU at designated rpm/throttle conditions. Notorious for failing if not maintained or in areas with snow/ice/road treatment. Sounds like you basically have a blow-off valve to open the second pipe. Sounds neat.
I wonder whether the diameter will cost bottom end torque (unless you're forced induction) but someone will probably jump on me for that. No dice on equal-length primaries for the headers? Its easy to be a critic, right? Seriously, nice llooking system, will be great to see the results. I think you're right that it will be loud (I think the Burns mufflers only shave 2-3 Db, tops), but that meets some people's approbation.

MarkRobinson

Gorgeous: that will sound incredible!

928SS

VERY NICE!!!

Chuck Schreiber

Greg,

Very nice!
Couple of questions, going from the single to the duel, tell me about the heat sheilds you had to add and did they bolt right up? Next, the 2 valve you're puting in, is it a 5.8 as you said in your above post??

Dude, you got me thinking!!

slate blue

Hi Chuck, going from single to dual is a very difficult job but I think we have previously discussed the battery box issue. Other than that, here is my thinking, the heat shields are an issue on the right hand side, my car at present doesn't have one, it does have the shields at the rear, you need to change your fuel tank cradle, but you can then fit that shield and the later battery box shield. The heat shields off the S4 etc won't fit the early cars! That came as a shock to me, the car's body is different underneath.

What am I going to do? Well I have two options, my first preference is to ceramic coat that side, also remember that side only operates on my car at wide open throttle, you should have good air flow when that is happening. Second is to build a custom shield, probably not that difficult but I like it to look factory and not some bodge job.

As to the engine I have posted some info before, I had the parts for sale when my block failed while it was being welded, it looks like I can get another block and I thought oh well I should build it but my goal is to build a 6.6 liter but that engine is twice as expensive as the 5.8 liter. I would have thought that we could get 425 to 450 hp from the 5.8 liter. The heads flow well for a 2 valver, around 285 cfm at 0.550" lift so the airflow is there to support decent hp levels. Also the other bit about this engine is that the componants are really light, around 8 kgs is saved internally.

Cheers Greg

PorKen

Greg,

That looks awesome!

I was just out under my car looking at my old 3" single that I welded up a while back. It looks ****e compared to yours. I'll just have to redo the whole thing now!

BTW: I'm with Andrew, more pics of the Sheila, mate.

toofast928

Very nice!