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Old 07-09-2009, 03:40 PM   #1
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Default DIY exhaust and water injection setup

Hey, just thought id post up some pictures of the exhaust I just made and the WI system. I used a harbor freight 90 amp welder on the exhaust, worked great! The pipe is aluminized steel. Overall I spent about $200 including the welder. Also, V band clamps rock! The sound is low and smooth, sounds really good to me.


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Old 07-09-2009, 05:40 PM   #2
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What were your settings on the welder? I have the same one and am about to start playing with it.
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Old 07-09-2009, 06:16 PM   #3
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If that's all 3" I think we probably used the same muffler. I'm very pleased with the 6" can Magnaflow. It's almost too quiet. Nice DIY.

Michael
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Old 07-10-2009, 12:15 AM   #4
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Quote:
Originally Posted by zoomin View Post
What were your settings on the welder? I have the same one and am about to start playing with it.
I used 16 gauge tube, and I commonly used the high amperage, and the wire feed around 7 or 8.

If you need to fill a gap, switch to low to avoid making the hole larger, and wire feed around 6. then quickly circle around the hole, making it smaller and smaller every pass till its filled.

eaither way, your wire feed will always be above 5. Oh, for the hangers, high power and 8-9 wire feed, it can get a solid weld on 3/8 round stock with only one pass.


Micheal, yep thats the one. Sounds really good, especially under full throttle.
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Old 07-10-2009, 12:26 AM   #5
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Thanks for the motivating pictures and info, I hope to get some stuff done this weekend!!
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Old 07-10-2009, 12:36 AM   #6
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Thanks for the motivating pictures and info, I hope to get some stuff done this weekend!!
No problem. I don't know if you've welded before, but be sure to do some practice first. Did you get any extended warintee for it? The 3 year one was like $20, so I got it, figured id "trade it in" in a couple years and get the newer model lol.
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Old 07-10-2009, 01:09 AM   #7
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I have a bunch of scrap to play with, and definitely got the extended warranty!
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Old 07-10-2009, 01:24 AM   #8
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FCAW is so ugly. Makes me want to throw up everytime i see these welds... Unless of course its on a structural building then i admire it. Good fabbing skills though!
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Old 07-10-2009, 01:55 AM   #9
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lol, whatever it holds good. I could take the time to grind it and stuff, but it doesent matter to me. The turbo flange I did with a mig, but I only had it for a day lol.

Maybe if I convince Pitt's FSAE team to let me borrow the TIG...


Here is the best weld I got with the flux core...

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And the downpipe (yes I used a miter saw with a metal disk to cut the pipe lol)....

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Old 07-10-2009, 01:59 AM   #10
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My plan is to tack the visible flanges with the 90 amp and bring it elsewhere for finishing, the unseen ones I will care less about.
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Old 07-10-2009, 08:04 AM   #11
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what kind of pump is that for your WI?
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Old 07-10-2009, 08:43 AM   #12
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Next time you're out shopping and buying material to weld something, grab some Anti-Spatter Gel or a slag hammer. Sheesh!

A weld is a weld, if it hold that's good enough. I'd spray paint them w/ some rustoleum if it were me. It'll prolong the life.
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Old 07-10-2009, 07:03 PM   #13
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Ok i need more details on where you got all your parts cause that is right in my budget (already have the welder). Where did you get your piping and muffler? V-band?
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Old 07-11-2009, 03:30 PM   #14
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The pump is a Shurflo 8009-543-236.


I got the bends off of mandrel bending solutions Mandrel Bending Solutions Home Page.

They were cheap, and because im in PA shipping was fast.



The V band clamps are these 3" MILD STEEL V-BAND CLAMP FLANGE KIT TURBO TO DOWNPIPE:eBay Motors (item 110410743083 end time Jul-11-09 19:12:24 PDT)

Worked well enough, make sure to used some copper RTV when you clamp them together.
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Old 07-11-2009, 04:28 PM   #15
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what did the water do to EGT?
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Old 07-13-2009, 12:15 AM   #16
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Quote:
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what did the water do to EGT?
Cant tell ya, I dont have a EGT gauge
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Old 07-13-2009, 02:49 AM   #17
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I just rememeberd this thread got me motivated to install my WI. Thanks
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Old 07-13-2009, 07:47 PM   #18
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I just rememeberd this thread got me motivated to install my WI. Thanks
haha no problem, I need to go get some distilled water actually...
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Old 07-13-2009, 08:17 PM   #19
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Windshield wiper fluid FTMFW!
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