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Discussion Starter #1
As many of you are aware my E is turbo-ed. I currently have a 2.5" cat back for the turbo, and a 1.75" dump tube on the wastegate.

Well recently my cat went bad, and shortly afterward my muffler started to come apart inside. It's rattling like crazy and not only is it annoying, but rattles kill O2 sensors. So it's time to remedy the situation.

Here's some of the goodies I've picked up so far.
The big tubing is 3.25" and the smaller is 2.0"
everything is stainless
enjoy





 

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Discussion Starter #2
more pictures

I love the look of tig welds. This piece is where the wastegate will connect into the exhaust





 

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whoa that look really good. I cant wait to see that on the E. I dont see an electric cutout tho ;-)
 

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Discussion Starter #4
No need for a cutout when you use 3.25" tubing. Those electric actuators are in short supply everywhere anyway. I don't have the full layout mapped out yet but i have the rough planning done and enough material to improvise the rest. I'm hoping to have it done in about 2-3 weeks. This weekend is the last of lift access mtb till spring. And there is a car that has to be at least partially put back together so I can use the lift.
 

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Discussion Starter #6
Yeah, 3" Borla xr-1 16" oval case. It's full 304 stainless including the filler mesh. It's supposed to be one of the highest flowing muffler on the market. Should be here tommorrow.
 

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Discussion Starter #8
Remember exhaust pipes are measured OD not ID. So yeah I'm hoping they will either butt together or slip together. Either way, nothing a little molten 308 filler can't handle.
 

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Discussion Starter #10
A little but, I learned on aluminum. So steel is easy compaired to that. I actually only did a couple practice welds before I did that piece. The trick is weld hot and fast, use flux inside the welds.
 

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Discussion Starter #12
oh, that's good to know mufflers are ID. I still don't have it the UPS guy never showed today. Yeah, I'm going out the side again.
 

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Discussion Starter #14
this will most likely quiet the car down a little. Wastegate dump tubes are LOUD
 

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What do you need the 2 inch for? Screamer pipe?
 

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Discussion Starter #16
Kind of. I'm going to recirculate the wastegate. I'm tired of listening to the screamer that I have now
 

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Discussion Starter #17
more pictures

I've been doing a few things in advance because I have to fill my welding tank and it wasn't completely empty yet. I got the Y-pipe where the wastegate will connect finished and welded on the flex pipe. I also ported out the inside of the Y so the exhaust has a smooth transition into the main pipe.

This is still just the basic setup, not everything is welded yet, I just need to visualize the lay out.





 

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does it neck down just befor the muff,or is that just the shiney pic's& an opticle olusion ? vroom vroom vroom........................weeeeeeeeeeee weeeeeeeeeee weeeeeeeeeeeeee weeeeeeeeeeeeeeeeeeeeeeeeeeeeee
 

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Discussion Starter #19
it does step down a tiny bit. It's 1/3 optical illusion, 1/3 step down to 3.0" ID, and 1/3 variation in tubing thickness. The shiny stuff I'm using is pretty thick it probably has an ID of 3 1/8"
 
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