Stainless steel exhaust

I made this yesterday, it's taken me a short while to collect the bits but it's finally done! It consists of:

-316 stainless 6mm x 75mm x 75mm plate which I drilled four 8mm holes and one 50mm hole
-2 50mm stainless tubes with a ~35° bend in them
-Stainless 'poly-zhaust'

I got the plate cut especially by a company called 'metalsdirectuk' who are on ebay and have a website, their ebay id is metalsdirectuk. They were helpful and a good price, delivery was very quick (no connection, just a happy customer).

The box came from ebay as well, it's a 304 perforated stainless tube inside a polycarbonate shell, it feels very solid and chunky. I chose this model as it fits nicely in place of the original box.

The tubing of the rest of the exhaust is 1.75" however the standard silencer is restictive and tailpipe is about 1.25" for some reason. The most common and cost effective upgrade is to just replace the box, the rest can stay the same. However I can't afford a stainless aftermarket free flow silencer, so I built this for about half the price and a lot more satisfaction.

I drove it this morning and at idle it is pretty much silent, it's about the same as standard when cruising but when at full throttle and couple of thousand rpm it sounds lovely! The next job is some decent stainless hangars in the right place, I used the old with with a bit of timing belt wedged in it

The welding isn't great but it's my first time with stainless and i'm also not used to welding thin stuff like this, mostly i've only done 3mm or more. The bolts are A4 stainless with stainless spring washers and nuts from a boat chandlery near me, they are good because they're open saturday and sunday too. I cut the 50mm with a starrett 51mm holesaw and A-2 arbor, this provided an interference perfect fit for the tube. This took an entire day to cut through because my 1000w bosch power drill would get too hot so could only do short bursts with huge breaks.

nice work mate, bin thinking of doing the same on my jeep as its something that only needs doing once, a good idea especially if your keeping the motor

shoulda made the whole thing bigger bore. Should be an easy job on a landy

I used to run my 2.5Diesel 2A through a cherry bomb exhaust that was mounted underneath the passenger seat (It was at the back like yours where the proper silencer used to be but i shortened it due to it snapping a few times!).

Boy that was loud! The diesel sounded quite impressive when you got some speed up and went past a wall!

I had to put a proper exhaust back after my ears started to hurt and i dont think it was impressing the neighbours much!

My local parts store only carried Cherry Bomb as far as performance. He handed me the box:

Me: "That can't be right, it is half the size of the stock muffler and the stock one is not very big."
They: "They are all that size"
Me: "Must be load as $hit"
They: "yes, real loud"
Me: "The ports are not right, supposed to be center in/offset out"
They: "They are all offset in/out"

They said they don't carry Flowmaster ("flow what"). Weeks later I see 4 sitting on the shelf, dusty, probably have been there years and they are clueless as to what they are.

Drove a little further to "the good parts store" and they carried Flowmaster. Ordered a Delta 44, had it next day.

Installed on my Jeep, nice and quiet but has deep sound. Some resonances. Made big diff in responsiveness.

At least when the chassis collapses the exhaust will be left sat there gleaming!

I fancy a pair of flowmaster 40's on the Chevy when the current boxes rust out, it'll also give me an excuse to stick some decent headers on at the same time. The boxes on there at the moment just aren't loud enough for me. Who needs a stereo when you have 5.7L's of V8 to listen to!

It still works!

It's not as loud as a cherry bomb, it's pretty much the same as standard most of the time it's only when I put my foot down it's gets a bit loud.

Oh, the timing belt - it melted.

However I can't afford a stainless aftermarket free flow silencer,

Guys, If I can help with anything exhaust wise give me a call. Im sure a bit of discount can be arranged for european forum users/members :-)

www.dynoflow.co.uk & www.aeroexhaust.co.uk




[worried look] A PLASTIC SILENCER ...Thats a new one on me .... What ever next...


good work with the system, its not fun Mig'n under a car...

obviously not taking any money away from Fin, but i`ve got a pair of CCR muff diver`s see here http://www.custom-chrome.co.uk/shop/catalog/product_info.php?products_id=127 used but still perfectly good with a clean up, there yours FOC if your around this way and want them.

Fin said:

[worried look] A PLASTIC SILENCER ...Thats a new one on me .... What ever next...

Click to expand...

Well, lots of bike cans (and the can that'll go on my Cinq tub) are carbon fibre, which is, effectively, polyester or epoxy re-inforcing a carbon matrix. But that one certainly piqued my interest. Any details?

Cheers for the offers JayRS4, i'm not that far away but I am going to go for a stainless one personally - loads of mild steel ones have fallen apart under it already

Fingers99 - look here http://www.poly-zhaust.com/

It has ceramic insulators between the pipe and the plastic, these bonding failed so it rotated around these, then the bonding between the two halves of the casing failed and it fell in half, then touched the pipe in various places and melted. Useless.

Polycarbonate is some good plastic aswell, certainly takes some beating.

The hole saw, a 1000w drill shouldn't struggle with a 51mm hole saw, perhaps you were running it a bit fast and a bit thin on the cutting oil?

I'll resurrect this old thread, as part of the repairs to the Land Rover I finally built a new exhaust. I put the standard one back on after the plastic one fell apart.

I obviously kept the stainless pipe I built so I bought a 2" straight through silencer off of ebay (6" round, 14" long). I cut out the perforated tube that was the centre of the old silencer and welded the new one in the gap. I had to weld it all slightly squiffy as the old one had an offset in/out and the new one doesn't. I then bent up, welded and drilled a bracket from stainless flat bar and welded that on. This came together really quickly, and works nicely.

for joints i use these

Thats far too posh to go near a land rover, it's like a work of art...

that diff guards a bit of a beast!
nice bit'o'welding too

Thanks!

I made the guard, they are used in america on Dana 66 axles all the time, very common over there, not here and expensive to import really.

I made a thread about it here