Exhaust system
We didn't have stainless rod to TIG with for the thinner stainless tubing so all that could be completed was the heavier flanges and tacks to hold the pieces in place. You can see where this downpipe must fit. Clearance isn't generous here but its still allows for a heat shield on the firewall attached in the same place Mazda put the mounting tabs.
This is a TiAL 38MM wastegate with a 1 bar spring (14.5psi)
The wastegate will be controlled by a Greddy Profec B Spec II Electronic Boost Controller
The first downpipe shown above is the current part on the truck. The one shown below was originally made to use the internal wastegate inside the TD05H turbine housing but this was changed. The rest of the exhaust shown below remains the same. We designed the system from the start to have the ability to change downpipes easily but didn't know this was going to happen so fast. The swap worked just as it was supposed to, the new downpipe fits right in with the rest of the system with no changes or adjustments.
The exhaust system was made with one 3" mandrel "U" bend by Dynamax and a 3" universal mandrel bent exhaust system by Flowmaster containing 4 pre-bent tubes or various angles, both sold by Jegs in Columbus, Ohio along with three Ebay items: a stainless Borla muffler, a stainless resonator and a stainless flex joint (with non-stainless ends), the resonator and muffler are clamped on, there is one 3 bolt flange mid-way in the downpipe and all tubes are welded together
Coming off the turbine housing we used a part of the "U" bend for the first section of the downpipe and a short left over 2" stub from some intercooling from a previous project for a wastegate pipe running down to a 3 bolt flange (flange will be install in a couple days it is not in these pictures) we cut off a short section to make the 3 bolt flange in a place it would be easiest to disconnect from inside the engine bay (this cut off part we used as the inlet for the resonator, see below)
then a receiver 3 bolt flange welded to the end of one of the Flowmaster sections, there was a cut made after the tube leveled out to weld in the stainless steel flex pipe and the remainder of the section was welded to the other end of the flex
then two more of the four tubes from the Flowmaster kit were used to move the tubing from the right side to the left just past the transfer case. So far, the bends were not changed, welded or bent from what came in the "kit". One end of each of the tubes in the kit is swelled to allow a slip connection using a clamp, however; we are only using clamps on the inlet/outlet of the muffler and resonator as they are stainless. The flex pipe came with steel tubes on each end. at this point is where the muffler was put in.
The rest of the "U" bend we started with in making the downpipe, we used to raise the tube up higher just after we were past the cab and slightly more inside of the frame. We did this to make use of the factory mounting points. That was done by cutting two 45 degree sections from what was left of the "U" and reversing one piece and in the end we had about a 4" section of the "U" to throw away.
From the final piece of the "kit" we cut off a section to use for the outlet of the resonator and the left over part from the downpipe as the inlet. these parts are welded in place. the remainder of the last Flowmaster tube was reversed and used for the tailpipe to exit just in front of the rear bumper
To see this same Flowmaster kit as we used on a Conquest/Starion. We only need the extra "U" bend in this one because we had to move the tubing from one side of the vehicle to the other because of where the gas tank is located and then to raise it higher for more rear axle clearance neither of which is necessary in a Conquest/Starion system.
prices do not include shipping:
15.99 turbine flange
65.99 Flowmaster kit
19.99 Dynamax "U" Bend
79.00 Muffler
39.95 Resonator
31.00 4 stainless band clamps
13.50 2-3 bolt flanges
265.42 total
Here's the stuff; click to enlarge:
the bungs for the 02 sensors being welded in
