Click here to sign up  Click here to go to the galleries  Click here to go to the code of conduct  Click here to go to the video page  Click here to go to the SW Meets page

Thread: New exhaust

Page 2 of 3 FirstFirst 1 2 3 LastLast
Results 11 to 20 of 23
  1. #11 Re: New exhaust 
    frequent forum contributor Club Member Patrick's Avatar
    Join Date
    Nov 2011
    Posts
    301
    Small update today, prepared the backbox output to fit the tips in the right place :

    Step 14: Cut down the output pipes, otherwise the tips would stick out too far.



    Step 15: Tip test fit, could move these back further by cutting the tip input down a little which would make the hole bigger.



    Step 16: Test fit on car, itís just push fit to at this point



    Opened up the cover thatís over the mechanisum which actuates the volume flap



    View from the top, position seems quite good here



    View of the inside of the back box, the perforated metal is the bypass output



    The other side, the hole show is the bypass, the perforated tube up to the flap works much like the straight though magnaflow back boxes I took off when it is open.

    Reply With Quote  
     

  2. #12 Re: New exhaust 
    frequent forum contributor Club Member Alan c's Avatar
    Join Date
    Jul 2013
    Location
    Horsell - near Woking in Surrey
    Posts
    330
    Great job. Watch air flow over car pulling in exhaust fumes when roof down. I had similar system fitted and get a smell of exhaust during around town - ok on runs. You would think air flow would take it away obviously eddy's create a problem
    Reply With Quote  
     

  3. #13 Re: New exhaust 
    frequent forum contributor Club Member Alan c's Avatar
    Join Date
    Jul 2013
    Location
    Horsell - near Woking in Surrey
    Posts
    330
    My previous system had a bend in tail pipe to direct it to the side
    Reply With Quote  
     

  4. #14 Re: New exhaust 
    frequent forum contributor Club Member Patrick's Avatar
    Join Date
    Nov 2011
    Posts
    301
    Thanks Alan good tip, the old exhaust did get some fumes in the cabin. I'm planning on sealing up the rear tub better to see if that improves things, if not making changes is not too hard - could use some bends in and/or use different tip style. Could go full TVR and exit out the side at the back, not sure how that would look on the Sportster though!
    Reply With Quote  
     

  5. #15 Re: New exhaust 
    frequent forum contributor Club Member angusgrooby's Avatar
    Join Date
    Nov 2011
    Location
    Peterborough
    Posts
    96
    Hi Patrick looking good, thank you for the detailed info on the welder you are using and the links all very interesting I just need to convince the wife now and a good project to justify buying a tig welder now. ????
    Reply With Quote  
     

  6. #16 Re: New exhaust 
    frequent forum contributor Club Member Patrick's Avatar
    Join Date
    Nov 2011
    Posts
    301
    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.
    Reply With Quote  
     

  7. #17 Re: New exhaust 
    frequent forum contributor Club Member Patrick's Avatar
    Join Date
    Nov 2011
    Posts
    301
    Built the other side of the exhaust today. Welding is Ďbetterí than when I started but still pretty uneven. I canít weld too far consistently around the curve yet. Did punch a few holes in the metal in places which results in having to Ďglobí 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 45ļ 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 itís 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, shouldnít be needed with v-bands but Iíd 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 thatís a whole new level of noise (did try running it with just the header and you need to wear ear protectionÖ)



    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 itís quieter than old the jetex micro bullet muffers + the large magnaflow boxes. Open itís 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.
    Reply With Quote  
     

  8. #18 Re: New exhaust 
    frequent forum contributor Club Member Patrick's Avatar
    Join Date
    Nov 2011
    Posts
    301
    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.
    Reply With Quote  
     

  9. #19 Re: New exhaust 
    frequent forum contributor Club Member Patrick's Avatar
    Join Date
    Nov 2011
    Posts
    301
    Video (obligatory no exhaust clip right at the end when everthing was off):

    Reply With Quote  
     

  10. #20 Re: New exhaust 
    frequent forum contributor Club Member
    Join Date
    Jan 2016
    Location
    Rugby
    Posts
    192
    You should have left them off (till the MOT)....
    2000 Marlin Cabrio; 2.0 L Burton Pinto in Ford Nightfire Red with Magnolia leather interior.

    http://www.marlinownersclub.com/wppg...&image_id=2349
    Reply With Quote  
     

Similar Threads

  1. New Exhaust
    By charles44 in forum What did you do with your Marlin today
    Replies: 1
    Last Post: 07-08-2016, 05:33 PM
  2. Replies: 0
    Last Post: 05-05-2015, 08:19 PM
  3. FMB new exhaust
    By djj_engineer in forum What did you do with your Marlin today
    Replies: 0
    Last Post: 12-02-2015, 05:26 PM
  4. which exhaust
    By rooha in forum Roadster
    Replies: 8
    Last Post: 14-08-2014, 01:34 PM
  5. Exhaust
    By amalgamated users from prior forum in forum Roadster
    Replies: 1
    Last Post: 19-04-2007, 12:39 PM
Bookmarks
Bookmarks
Posting Permissions
  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •