Custom 3" Exhaust
08-06-2008, 11:29 PM
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Custom 3" Exhaust
The header is from a 96' Kia Sephia. Originally the 4 primaries combined into a cone that went from 3" to 2", then to a flange. Well I cut it after the pipes merged and welded a 3" pipe to it. This is what I got done so far. Yes my welding skillz are not great, but it will work (dear lord we prey ). Arc welding FTW. Using 3/16 7018's too, which is a penetrating rod. Gotta go fast or it burns a big hole quick. Plan is to have the header slip into place and bolt on. Then the rest of the exhaust system will slip on and clamp to it. Hoping to make use of the stock exhaust hangers. Still hoping to squeeze three glasspacks under the car before the muffler.
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08-07-2008, 12:53 PM
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I'm going FI soon, but I didn't finish my SC project yet. So I'm building the exhaust 3" cause I'll need it soon enough. 
Got the 3 glasspacks under there just barely. Pics later when it's all done, but they BARELY fit! Got it to the differential right now. Gotta add a hanger and keep on going.
Got the 3 glasspacks under there just barely. Pics later when it's all done, but they BARELY fit! Got it to the differential right now. Gotta add a hanger and keep on going.
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08-07-2008, 10:14 PM
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Got the exhaust mostly finished today. Only have one hanger holding it right now, so I gotta add a few more tomorrow. Got rained out today or I would have finished.
In short, it's a header with a 3" collector and 3" all the way to the bumper. No catalytic converter. I have first a 24" body Cherry Bomb glasspack that slips onto the header. I mean, the 3" pipe from the header snakes down to the bottom of the car and as SOON as it gets there, Bam, the glasspack goes on. I even cut off the 3" they weld on either end and shortened it up some so I'd have room for 3 glasspacks.
I then cut the extra 3" off the back of that one at an angle, and then fitted a 27" core glasspack. Then did it again with another 27" core glasspack. By now I'm at the rear differential.
I then weld a bend, a 3.5" piece of straight pipe, and another bend that goes into the Magnaflow Muffler. Note, the 3.5" piece of pipe mentioned is the longest piece of straight 3" exhaust tubing I used for my exhaust and it was cut off of a bend. The muffler is mounted in the "45 degree" method. Then it turns out and goes to a 3" pipe out the bumper.
So I still have a full stick of 3" exhaust tubing I bought and never even used.
Might try to return it I guess. I spent about 200 on mufflers, 30 on welding rods, 70 on mandrel bends, 15 on the header, and 15 on clamps and a coupler. So I guess this is my $330 DIY exhaust system. Only used two 45's and two 90's in the mandrel bends builders kit. Still got the two 180's.
So I fired it up and....
Wait for it....
It's like really ******* quiet. It's a spec quieter than stock. I'm sure once the glasspacks and muffler break in it will get a little louder though. Tone is quiet and very Very VERY deep. I like.
EDIT: Pics were taken at night so yeah I know they suck. Car is sitting on my homemade car ramp. Puts the car 20" in the air. Made running the exhaust a lot easier than working off of jack stands.
In short, it's a header with a 3" collector and 3" all the way to the bumper. No catalytic converter. I have first a 24" body Cherry Bomb glasspack that slips onto the header. I mean, the 3" pipe from the header snakes down to the bottom of the car and as SOON as it gets there, Bam, the glasspack goes on. I even cut off the 3" they weld on either end and shortened it up some so I'd have room for 3 glasspacks.
I then cut the extra 3" off the back of that one at an angle, and then fitted a 27" core glasspack. Then did it again with another 27" core glasspack. By now I'm at the rear differential.
I then weld a bend, a 3.5" piece of straight pipe, and another bend that goes into the Magnaflow Muffler. Note, the 3.5" piece of pipe mentioned is the longest piece of straight 3" exhaust tubing I used for my exhaust and it was cut off of a bend. The muffler is mounted in the "45 degree" method. Then it turns out and goes to a 3" pipe out the bumper.
So I still have a full stick of 3" exhaust tubing I bought and never even used.
Might try to return it I guess. I spent about 200 on mufflers, 30 on welding rods, 70 on mandrel bends, 15 on the header, and 15 on clamps and a coupler. So I guess this is my $330 DIY exhaust system. Only used two 45's and two 90's in the mandrel bends builders kit. Still got the two 180's. So I fired it up and....
Wait for it....
It's like really ******* quiet. It's a spec quieter than stock. I'm sure once the glasspacks and muffler break in it will get a little louder though. Tone is quiet and very Very VERY deep. I like.
EDIT: Pics were taken at night so yeah I know they suck. Car is sitting on my homemade car ramp. Puts the car 20" in the air. Made running the exhaust a lot easier than working off of jack stands.
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