47 replies to this topic

[FLD]

My wagon needs a new exhaust. The VSE (Vauxhall Sh1te Exhaust) is just too loud. Thing is 1600 quid for a full system is just outrageous IMO. Especially when I know that one of our favourite suppliers outsources the manufacture then just adds on 100% mark up. Its just a bit too cheeky that. Anyway, I found 90 degree stainless bends at 6.04 each and being tight I figured I have a go.

Laser cut flange


Bolted into my jig (made from OE manifold)


Collector flange welded solid round the inside / bottom….


….and tacked round the outside / top to stop it cracking off (fnnaarrr cracking off!!)


Then skimmed off to make sure its flat


45 degree bend ground up for the collector


All four looks like this. I was too tight to buy one of those hydroformed 4 into 1 collectors.



Into the jig, my god its going to be tight!

[FLD]

Primary 1 tacked in


Primary 2 tacked in, had to change collector to get the right length on this one.


Primary 3 tacked in. This one is tight on 1 and is a nightmare to cram the length in


Primary 4 not too bad this one


Nearly done now, out of the jig for final bits of welding.


I’ve ground of the weld tops to make it all smooth and I’ll get it blasted so it has a uniform satin finish. Thing is I’m not quite sure its up to it. I know its not on parr with the commercial manifolds but fingers crossed it does the job. Cat section is also ongoing. Downside is I cant find a universal silencer box that’s an appropriate size. Might actually have to pay for that!

Cost of manifold was less than 100 quid. No I wont make another one.

[Nelly Vx]

Thought you had one these guys doing the welding
good effort though

[slindborg]

I actually want your babies lol thats fcuking ace!!! Might try the same with Mild

[FLD]

Thought you had one these guys doing the welding
good effort though

Yeah, its been a while (around 10 years!!!) since I've done ANY welding. Recently figured out i've got it cranked up a bit high. Turned it down and its a bit better. Typical when its nearly done.

Is that one vote for scrap it and buy one you tight ass?

[FLD]

I actually want your babies lol



thats fcuking ace!!!

Might try the same with Mild

Not sure about babies but you can have my jig if you want? Flanges are around 35 quid.

[MrSimba]

I'm amazed at the skills people on here have! Thats a superb job done there Though there's about 50 people wanting to see if you can do them each one for £200...

Edited by MrSimba, 18 March 2010 - 08:55 PM.

[Nelly Vx]

Don't scrap it !!!! Group buy

[slindborg]

damn it 3.5 hr drive away. How did you find welding the pipes to the collector when the rest were in the way?

[FLD]

Thought you had one these guys doing the welding
good effort though

Just figured this out, its my barbeque in the background there. Originall thought it was my dodgy welding!

[FLD]

damn it 3.5 hr drive away.

How did you find welding the pipes to the collector when the rest were in the way?

Not done the centre yet, small ceramic and pile in lots of filler rod should do it.

[slindborg]

oh, might be a bit pricey but proof you can get the bits http://www.merlinmot..._229/index.html where did you get your bends from?

[FLD]

oh, might be a bit pricey but proof you can get the bits http://www.merlinmot..._229/index.html



where did you get your bends from?

From these guys on ebay
http://cgi.ebay.co.u...=item4a98e6039c

Mines in 1.75" but I think 1.5" would be far easier.

[Nelly Vx]

Thought you had one these guys doing the welding
good effort though

Just figured this out, its my barbeque in the background there. Originall thought it was my dodgy welding!

LMAO Nothing wrong with your welding

[Exmantaa]

NICE modding, but wondering why you stick to the short OEM 4-1 header length when doing a full custom job here..

[Welshiejon]

if you had purged the pipes with a steady flow of gas it would have welded beter but it dont look far off

[FLD]

NICE modding, but wondering why you stick to the short OEM 4-1 header length when doing a full custom job here..

I did consider that. The reason I stuck to that layout was that if I got fed up of it and decided to buy the rest theres a lot more choice when sticking to the oe breaks rather than wherever else I ended up.

Did consider back gassing too but Wanted it done quicker. There were some big gaps and I didn't clean up before welding either. CAA people would have a field day with it!!

[RobNA]

Nice work

[Nev]

Good effort This kind of DIY thing is important to reveal just how outragous 1500 for an exhuast is....

Edited by Nev, 20 March 2010 - 09:20 AM.

[The Batman]

awesome work, i wish i could do stuff like that!