New exhaust

[Patrick]

Re: New exhaust

There are so many things around the house that a TIG welder could fix

It took me a long time convince myself I should invest in the TIG welder, once you've bought acessories, gas, supplies, a good helmet etc it does start to add up quite a bit.

[Patrick]

Re: New exhaust

Built the other side of the exhaust today. Welding is ‘better’ than when I started but still pretty uneven. I can’t weld too far consistently around the curve yet. Did punch a few holes in the metal in places which results in having to ‘glob’ in filler rod to build it back up again. This part was back gassed as on the others before as it was a butt joint.



The 45º and straight pieces are sleeve fit, have welded these too so less clamps are needed. It also cuts down on potential exhaust leaks.



Once the two back boxes were hung I used some boxes and various peices of wood to hold the tips in place at the right height, this is with the car on the ground. Nothing on the Sportster is straight so this was done visually.



I used a piece of angle metal to line the tops and ends of the tips up. This helped make sure the tips were aligned straight with the ground, with each other and spaced from the back of the car.



Welding the tips on was a bit tricky, blew a few holes in the metal especially where the gaps were bigger. The left box alignment is slighly off, but it’s not visible once mounted and the tips are in the right place visually.



Both exhaust pipes mounted, the v-bands are visible in this shot. I used a tiny bit of exhaust paste on the mating surface, shouldn’t be needed with v-bands but I’d rather not have to take them off again! Also visible the zip tie exhaust hanger, nothing like attaching your exhaust to your suspension ;o) Kinds tempted to make some straight pipes that can be put in place of the back boxes, but that’s a whole new level of noise (did try running it with just the header and you need to wear ear protection…)



The more permanent hanger, this is a part is from pypes a US manfuacturer of exahust pipes. Had that left over from building an exhaust for the Mustang (http://www.mustang67.co.uk/exhaust-upgrade/) last year (welding with our 'cheap' clarke MIG, very messy process compared to TIG). Available at https://www.summitracing.com/



View from the otherside, wiring is hanging down. These cables need plumbing in properly and the metal shields putting back on the mufflers.



Car down on the ground from a low angle, the exahust tips are closer together than before (due to the input on the backbox being offset rather than in the middle).



The tips stick out a little further than the old ones, the wall thickness and slash cut work quite nicely.



Temporarily wired up the control box, and now for the noise test:

Closed it’s quieter than old the jetex micro bullet muffers + the large magnaflow boxes. Open it’s a bit of a beast, louder than before so that should be fun! It's pretty much were I wanted it to be, will see what it's like on the road once the wiring is done.

[Patrick]

Re: New exhaust

As I was busy Richard sorted the wiring out for the control box:

Wiring, inside the tub running along the tank with the rest of the rear loom



Wiring running along transmission tunnel, protected by a piece of fuel tubing to stop stray debris from damaging it.



Behind the fuse box, hooked in via 7.5amp fuse to an ignition feed



Located the control box in the same area just off the centre console.



Everything back in place under the dash



Just needs the rear putting back together again.

[Patrick]

Re: New exhaust

Video (obligatory no exhaust clip right at the end when everthing was off):

[Neil Johm Kirk]

Re: New exhaust

You should have left them off (till the MOT)....

[Patrick]

Re: New exhaust

lol yeah that sounds like a plan, doesn't make crusing quiet though.

The only down side of the quiet setting is that I can hear the water pump/ alternator belt making noise now :/

[272berry]

Re: New exhaust

Hi Patrick

An impressive thread and some quality work put in
I was wondering what you did at the header end did you retain the existing dual pipe manifold and CAT's
Regards Berry

[Patrick]

Re: New exhaust

Thanks Berry

I've had a BTB 6 branch stainless manifold and x-pipe on there for a long time so I've kept that. No CAT's on as it's a 1988 engine:






Chopped the ends of the x-pipe off that were made to fit the E30, welded on a straight piece and 45º to head over to the other side of the car.


Wrapped it to keep temps down near the brakes, there's also a headshield between the master cylinder and the manifold.