What did you buy your 991 today thread
#5431
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#5435
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I basically first took measurements of the exhaust pipe outlets. The oem S side outlets i think were 60mm OD (outer diameter) and my aftermarket exhaust (inner) outlets were 63mm OD. The aftermarket ones was actually easy to find a match as it's basically 2.5" OD, so i needed a pipe with a 2.5" ID (inner diameter) and it just slips over it. So I needed to find a pipe that would slip over both the S/aftermarket exhaust outlets and then somehow end with a 3" outlet for the tips
(AWE tips are actually 3.5" and it would work perfectly without me needing to do anything, but 1. they're double walled, 2. because they're double walled they look good at 3.5" but single wall 3.5" would be ridiculous looking, 3. AWE doesn't sell their tips separate from the full exhaust, 4. even if they did, it'd probably sell for $500+ which was the main reason i wanted to make my own)
I bought 4 exhaust adapters which are on average about 5" in length, and found the sizes i wanted specific for my application so that the adapter inlet can slide over the S/aftermarket outlets and the adapter outlet will then connect to a "tip" for the 3" outlet i wanted. Since the adapters by themselves were too short, i needed to extend the tip so i found a thin pipe with a 3" ID to slip over the adapter outlet. This in itself was difficult to find as most 3" pipes are 3" OD as it turns out and/or the pipe wall was way too thick. Once I had all the hardware pieces (adapters, pipes, clamps) thats where the real work began for me. I've drilled plenty of stuff, but apparently never drilled into stainless steel. I ended up breaking a handful of various drill bits. After some research online and talking to some people, stainless steel is one of the harder steels to cut/drill as it "work hardens". With tired hands and arms from trying to use a hand drill, i gave in and borrowed a friend's drill press. That made all the difference. With a fresh bit, i knocked out several holes that i needed in each of the stainless steel adapters. Then drilled corresponding holes in to the 3" pipe piece that is basically a sleeve and will serve as the "tip" visible from the rear of the car. I also cut slots into the inlet side of the adapter so that the clamps can squeeze down on it to the S/aftermarket outlets.
Before putting them on the car though, i disassembled everything and painted the parts in high-temp paint. after drying, i re-assembled it and connected the "tip" sleeve to the adapter using a combination of rivets and small bolt/nut. Then gave it another coat of paint so the rivet and bolt heads arent as visible. Then let the paint cure. Finally installed on car after!
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#5437
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#5438
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Join Date: Jul 2001
Location: Marineland FL
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#5440
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Join Date: Jul 2001
Location: Marineland FL
Posts: 12,511
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2,348 Posts
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#5442
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