Nothing to see here, just project Sisyphus, move along
05-19-2015, 11:02 AM
#1184
mkturbo.com
iTrader: (24)
Join Date: May 2006
Location: Charleston SC
Posts: 15,176
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Sunday was rather productive 
I drove up to Gesso's place and arrived much later than expected (about noon.) Pat didn't get there much before I did so I don't feel quite so bad for making people wait. We got started pretty much immediately by ripping out the stock exhaust.
Steady state highway cruise at 80~ish really has a tendency to heatsoak things. Great big fan really helped pull the heat out of the cast iron behemoth manifold so I could actually, you know, unbolt it.
Not shown, removal of stock exhaust, manifold and installation of turbo, manifold and downpipe.
Clever muffler mounting trick is clever. This gave us the support needed to figure out where to put the hangers. Not sure where Gesso saw that but holding up the giant magnaflow would have been a challenge without it.
Gesso using his magical machine to add said hangers to said muffler.
Much marking, cutting, thinking, cutting again, and tack welding thus commenced!
That's no joke... I think we were at this for something like 8 hours? Its insane. We made a lot of quick progress then got bogged down in fitting all the crazy little bendy sections.
My god, its full of stars!
Little lower angle for you. I was not sure that big *** 5" OD resonator was going to fit, but Gesso said we could do it, so we did it! You can see the flex joint in the ARTech downpipe just ahead of the resonator body.
A small variation on the classic "broomstick test." Exocet can be seen in the background mean-mugging. I think it wants to be next.
The fitment really is quite amazingly good, seeing as how none of us had ever done this before. I was sure to turn on the flash so I could make Jeffbuc's eye twitch
On the far left you can see the 180° we had to cheat about 3/4" out of the middle to get things to tuck properly. In the end it really should not matter.
Here she is on the ground. That far exhaust hanger will get triangulated before everything is said and done.
So much win! 3" from turbo to bumper. ALLTHEFLOWS! It should be epicly silent as well.
As promised, here is the shopping list:
1 x 4" x 5.25" Stainless Double Wall Angle 3" Inlet Tip ~ DT-30101
1 x 3.00" Mild Steel, 4.00" Radius, 16 Gauge, 180 Deg. Mandrel Bend ~ MS-16-300-400-180
2 x 3.00" Mild Steel, 4.00" Radius, 16 Gauge, 90 Degree Mandrel Bend ~ MS-16-300-400-090
2 x 3.00" Mild Steel, 4.00" Radius, 16 Gauge, 45 Degree Mandrel Bend ~ MS-16-300-400-045
2 x 3.00" Mild Steel, 4.00" Radius, 16 Gauge, 18 Degree Mandrel Bend ~ MS-16-300-400-018
2 x 3.00" Mild V-Band Assembly ~ VBAND-300-ASM-MS
4 x 3.00" OD, 16 Gauge, Mild Steel Straight Tube ~ MS-300-065
1 x Magnaflow PN 12579 5x11x22 C/C 3" I/O w/2.5" dual cores
1 x Vibrant PN 17950 Large Diameter Bottle Style Resonator, 3" I/O, 5" OD body
Notes:
Right now its tacked up and sitting on the floor in Gesso's garage. The plan is to backpurge the whole mess and he can finish tiging up the seams at his leisure. I'm hoping to be there so I can try to maybe screw up some of his hard work
Yeah, that's right, its mild. Come at me bro! It was significantly cheaper than stainless and for my needs, it will do just fine. I also found that there was a significant lack of angular diversity when I was hunting for stainless bends. I don't drive in the salt/snow so meh.
V-Bands will make it a lot more modular as well. If the front section with the resonator becomes too troublesome, we can remove it and replace it with a smaller one, or maybe even a high flow cat. This should also be modular enough that if I do something silly like changes horses midstream YET AGAIN the system can change with my frivolous desires.
Keep in mind this is all "practice" for when we spring into action on Gesso's car. I have a sneaking suspicion that exhaust will be very similar to this one. I think we will probably be building something for the Exo and Pat's car as well, depending on how things go.
Once again, I cannot thank Gesso and Pat Cleary enough for the mad romp through exhaust land. Time and effort are very much appreciated
I drove up to Gesso's place and arrived much later than expected (about noon.) Pat didn't get there much before I did so I don't feel quite so bad for making people wait. We got started pretty much immediately by ripping out the stock exhaust.
Steady state highway cruise at 80~ish really has a tendency to heatsoak things. Great big fan really helped pull the heat out of the cast iron behemoth manifold so I could actually, you know, unbolt it.
Not shown, removal of stock exhaust, manifold and installation of turbo, manifold and downpipe.
Clever muffler mounting trick is clever. This gave us the support needed to figure out where to put the hangers. Not sure where Gesso saw that but holding up the giant magnaflow would have been a challenge without it.
Gesso using his magical machine to add said hangers to said muffler.
Much marking, cutting, thinking, cutting again, and tack welding thus commenced!
That's no joke... I think we were at this for something like 8 hours? Its insane. We made a lot of quick progress then got bogged down in fitting all the crazy little bendy sections.
My god, its full of stars!
Little lower angle for you. I was not sure that big *** 5" OD resonator was going to fit, but Gesso said we could do it, so we did it! You can see the flex joint in the ARTech downpipe just ahead of the resonator body.
A small variation on the classic "broomstick test." Exocet can be seen in the background mean-mugging. I think it wants to be next.
The fitment really is quite amazingly good, seeing as how none of us had ever done this before. I was sure to turn on the flash so I could make Jeffbuc's eye twitch
On the far left you can see the 180° we had to cheat about 3/4" out of the middle to get things to tuck properly. In the end it really should not matter.
Here she is on the ground. That far exhaust hanger will get triangulated before everything is said and done.
So much win! 3" from turbo to bumper. ALLTHEFLOWS! It should be epicly silent as well.
As promised, here is the shopping list:
1 x 4" x 5.25" Stainless Double Wall Angle 3" Inlet Tip ~ DT-30101
1 x 3.00" Mild Steel, 4.00" Radius, 16 Gauge, 180 Deg. Mandrel Bend ~ MS-16-300-400-180
2 x 3.00" Mild Steel, 4.00" Radius, 16 Gauge, 90 Degree Mandrel Bend ~ MS-16-300-400-090
2 x 3.00" Mild Steel, 4.00" Radius, 16 Gauge, 45 Degree Mandrel Bend ~ MS-16-300-400-045
2 x 3.00" Mild Steel, 4.00" Radius, 16 Gauge, 18 Degree Mandrel Bend ~ MS-16-300-400-018
2 x 3.00" Mild V-Band Assembly ~ VBAND-300-ASM-MS
4 x 3.00" OD, 16 Gauge, Mild Steel Straight Tube ~ MS-300-065
1 x Magnaflow PN 12579 5x11x22 C/C 3" I/O w/2.5" dual cores
1 x Vibrant PN 17950 Large Diameter Bottle Style Resonator, 3" I/O, 5" OD body
Notes:
- I think we only used about 1' of the 4' of pipe that I purchased due to the resonators length
- We could have probably used at least one more 18 degree section
- I stole a chassis mounted hangar off another exhaust that was in Gesso's garage to add a 4th hangar location for the muffler
- A couple of cuts will need to be made somewhere along the system to add v-bands to make things a bit easier to remove.
Right now its tacked up and sitting on the floor in Gesso's garage. The plan is to backpurge the whole mess and he can finish tiging up the seams at his leisure. I'm hoping to be there so I can try to maybe screw up some of his hard work
Yeah, that's right, its mild. Come at me bro! It was significantly cheaper than stainless and for my needs, it will do just fine. I also found that there was a significant lack of angular diversity when I was hunting for stainless bends. I don't drive in the salt/snow so meh.
V-Bands will make it a lot more modular as well. If the front section with the resonator becomes too troublesome, we can remove it and replace it with a smaller one, or maybe even a high flow cat. This should also be modular enough that if I do something silly like changes horses midstream YET AGAIN the system can change with my frivolous desires.
Keep in mind this is all "practice" for when we spring into action on Gesso's car. I have a sneaking suspicion that exhaust will be very similar to this one. I think we will probably be building something for the Exo and Pat's car as well, depending on how things go.
Once again, I cannot thank Gesso and Pat Cleary enough for the mad romp through exhaust land. Time and effort are very much appreciated
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05-19-2015, 12:50 PM
#1185
Elite Member
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Join Date: Apr 2010
Location: Very NorCal
Posts: 10,441
Total Cats: 1,899
Thanks! I can't take all the credit, Gesso is the wizard here. We've been following your posts in the Fabulous Fab thread and taking notes. I wanted to thank you guys for all the pics
Thanks for all the comments/complements! Time to get the engine together so we can see what she sounds like.
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05-19-2015, 01:12 PM
#1187
The metal hanger mounts are cut and bent out of I believe 3/8" stainless rod? Gesso can confirm. It was like $10 for 3' of rod or $10 EACH for prebent hangars that only came in a 10 pack. That's just silly. In the end they went together super easy. We used all the OEM chassis mount points plus added one. I'm tempted to add another but we'll see. I need to get a pic of the one we added.
The 4th muffler hanger mount is just a generic muffler mount attached to the drivers side tie down point (up pretty high).
Even with the soft factory rubber the mounting is pretty stiff, I'm hopeful that it won't bang around.
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05-19-2015, 01:43 PM
#1191
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Join Date: Apr 2014
Location: Huntington, Indiana
Posts: 2,885
Total Cats: 616
What I want to know is who in the hell thinks they can call themselves Monk!?
It seems like a pretty decent forum. I need to do a little reading before my V8 ranger 5 speed swap.
It seems like a pretty decent forum. I need to do a little reading before my V8 ranger 5 speed swap.
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05-22-2015, 07:01 PM
#1198
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Join Date: Apr 2010
Location: Very NorCal
Posts: 10,441
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Oh yeah, ordered:
TR8 Intercooler 500HP- TREADSTONE PERFORMANCE
Amazon has made me INCREDIBLY impatient when it comes to shipping. I was really hoping for this to show up this week so I could work on plumbing and ductwork over the long weekend, but that ain't happenin'
Also, my FIC 650's are for sale if anyone cares: https://www.miataturbo.net/miata-par...cleaned-84516/ Maybe someone will buy them so I can prepare my car for future E85 shennanigans.
TR8 Intercooler 500HP- TREADSTONE PERFORMANCE
Amazon has made me INCREDIBLY impatient when it comes to shipping. I was really hoping for this to show up this week so I could work on plumbing and ductwork over the long weekend, but that ain't happenin'
Also, my FIC 650's are for sale if anyone cares: https://www.miataturbo.net/miata-par...cleaned-84516/ Maybe someone will buy them so I can prepare my car for future E85 shennanigans.
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