DIYish? Custom Single Exit Muffler Delete w/Video
 

So, I have wanted my car to be more audible since day one.

This weekend I decided to make it happen.

This could also serve as a DIY for those interested.

Parts Used:
1 - 18 inch section of 3" pipe - $6.98
1 - 2.5" to 3" expansion - $3.75
1 - 2 bolt, 2.5" flange - Already had one
1 - 12 inch section of 1/4" steel rod - Already had one



First undo the factory muffler. Two 14mm bolts, 4 hangers. Simple enough. Save the gasket or get a new one.

http://i42.tinypic.com/xnau5g.jpg

As you can see here, the exhaust enters the muffler at a weird angle. You can't just run a straight piece of pipe. You've got to get creative and after studying the Berks muffler delete my friend and I had to make it up as we went because we didn't have a pipe bender and pie cuts were not an option.

http://i43.tinypic.com/10mjy2a.jpg

What we found to work was cutting the 2.5" end of our expander at 15 degrees. Then, we tacked it up to the flange a few times to get the position right. This brought the tip down to exit the car.

http://i44.tinypic.com/9lcvi9.jpg
http://i41.tinypic.com/18etch.jpg
http://i44.tinypic.com/149b1he.jpg

We then cut the 3" pipe to desired length and cut it at an obnoxious angle. The other end went into the 3" side of the expansion joint and was welded up.

http://i41.tinypic.com/2r26jps.jpg
Then we had to devise a hanger that would keep the new tip from hitting and ultimately melting the plastic of the bumper. This was by far the hardest part as these exhaust systems are rather sturdy and don't like to move.

Here it was after all was said and done. It looks great and sounds amazing. I can post a video, but the sound gets super distorted though my camera and wouldn't do it justice.


http://i44.tinypic.com/2qsnw9k.jpg
http://i42.tinypic.com/29fv3ao.jpg


Then, just for fun we painted it gold....This step is definitely optional.


http://i40.tinypic.com/5ceg7d.jpg


All in all, it cost about $20 after the gold paint. Took a couple hours to fab up and get placed where I wanted it.

Some may like, some may not. I love it, and it is by far one of the best sounding FR-Ss I have heard. There is plenty of clearance and no heating issues on the bumper.

[ame="http://vimeo.com/70296813"]Video[/ame]

Any videos of how it sounds now?

I'll try to get a decent one tomorrow. The one I have now is distorted.

i love this kind of DIY stuff. nice work.

Thanks!





BTW, Video in original post now, it's quite distorted, but you get the idea.

oh.....

The "Oh of Disapproval?"

Just not sure if the weld to the stock flange will hold does you welder have gas

No. It doesn't. My friend welded it. They aren't the prettiest but, they are solid. Time will tell though. If they fail I'll hear it and I have the factory muffler still hopefully my bumper doesn't melt apart if thaf happens.

I am confident. He's welded exhaust stuff for me before. It's always been fine.

Plus there is a hanger that supports the pipe. It isn't just hanging.

Also the stock flanged wasn't used. It was a different flange. It is bolted to the factory exhaust just like the stock muffler.

Watch your legs if you are wearing shorts and accessing the trunk.

Old thread but... did the setup work alright without an additional hanger on the axleback portion? Most of the muffler deletes add a hanger the rearmost part.