Kurt:Exhaust

Starting with a universal kit from Jegs, we added a flex pipe, resonator, two 02 bungs and one plug, two 3-bolt flanges, a laser cut turbine outlet flange, one 1.5" Sch10 weld els and a muffler.

the goal is to make the complete system without needing any more tubing, or bends that comes in the kit

the parts that were added to the kit are the same parts that were added to the b2600 system except the car didn't require the additional U-bend  ( click here for that page )

and this is how was proceeded:

4 parts are in the "kit", using the one with the tightest bend, we cut that to make the downpipe

after that was cut, the shorter piece was turned around and slid onto the opposite end and slightly rotated inward.  the downpipe flange was bolted to the turbine housing then these parts were fitted

we held the next section under the car that the DP was to connect to and rotated the short end for a butt weld.

Then we tacked the two 3bolt flanges together ( to prevent warping and misalignment ) and slid those onto the upper section of the DP and then pushed on the second section of pipe we just did the butt weld on

then we added in the two 02 bungs ( and plugged the one ) and after we welded the 3-bolt flanges on, then we ground off the tack welds that held them in alignment

this makes for an upper downpipe section that can be unbolted from under the hood ( just like we did in the truck ) and it slips together to help seal and remain more stable than it would had we cut that extension off

then as you can see, we attached the flex section.  on the truck we attached the flex just after the DP, we chose to not put this in that location under the car to keep the pipe closer to the body but we still wanted a flex in the system

the next section, which is not pictured yet BECAUSE it's not been done will be from a straight section that was cut from 3rd piece of the kit and attached to the flex ( after a short 1-2" section of bend is attached ) and then the resonator will go inbetween the rear crossmember and the differential, the the remainder of that cut section turn 45 degrees out and the final section.  This necessary small bend before and after the flex is to move the tubing from along side the frame rail that is utilizing the factory heat shields under the car and then realign the tubing to the two indentations in the rear crossmember and differential carrier. All that is to keep the tube as close to the body as possible.  The last section will go around the rear edge of the gas tank and into the muffler.

OK, the muffler is here :