My custom built 76mm exhaust..long read

Discussion in 'Fiesta ST Engine Upgrades' started by Drifter, Mar 8, 2014.

  1. Drifter

    Drifter Member

    So, dropped the Driftmobile V2 off at KontrolFreakz for custom exhaust build. I will try and keep this thread going as a work in progress thread, so you guys can see it's not just a matter of slapping on a pipe.

    Really LOTS of work need to be done:


    Before all started

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    On the lift

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    Prepping started

    Need to remove engine cover, lights, induction and water bottle.

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    Wiper removal

    Need to removethe wipers and slide out the wiper blades

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    Remove induction:

    Need to remove induction to get access to the top bolt on the DP.

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    Now, need to get past that heat shield so we can access the DP.

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    more to come .....
     
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  3. Drifter

    Drifter Member

    Stock Down pipe and CAT

    What a fugly thing!!

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    Stock CAT Back

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    Bye Bye Stock Exhaust

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    High Spec heat wrap


    After a lengthy duscussion with PhillipI took his advice and asked him to heatwrap the DP, This high spec heat wrap.

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    Turbo Flange cut and ready

    This is for the new 76mm DP. Look at the workmanship, this guy doesn't rest.

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  4. Drifter

    Drifter Member

    Reducing the 85mm turbo flange exit to 76mm

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    Welded on inside

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    Double welded on outside to prohibit cracking and breakage

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  5. Drifter

    Drifter Member

    First bend welded into the system, completely seamless

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  6. Drifter

    Drifter Member

    Next up, 76 mm concertina flexi, triple welded through all three layers.

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  7. Drifter

    Drifter Member

    First lambda bung gets strategically placed

    A 18mm hole gets drilled and bung welded into place.

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  8. Drifter

    Drifter Member

    The experience comes in when you have to use pre-made Mandrel bends, where to cut them, how to cut them and at what angle to cut them, to make the system go
    in the direction you want, whilst using as little as possible bends to optimize flow to increase performance.

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    When you grind through the steel, it ends up with a very ugly edge. Every single cut gets belt sanded and de-burred to get a smooth weld with nothing protruding
    on the inside of the exhaust system.

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  9. Drifter

    Drifter Member

    Stainless Steel high flow resonator gets prepped.

    Double welded end pipes to make it easier to weld onto the system.

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  10. Drifter

    Drifter Member

    A few bends, some welds, a downstream lambda and a resonator.

    We are almost done with the down pipe. Phew!!!

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  11. Drifter

    Drifter Member

    Now a flange to split the system.

    We use V-band flanges as it also creates a seamless link.

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  12. Drifter

    Drifter Member

    An extension and two exhaust hangers. and you end up with a complete down pipe.

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    No, thats not me. It's Nishen from KontrolFreakz.
     
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  13. Drifter

    Drifter Member

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  14. Drifter

    Drifter Member

    Mini CAT fooler

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    Every single nut, bolt or sensor gets a dab of copper anti seize compound before they go back in.

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  15. Drifter

    Drifter Member

    Final fitment in place

    Now to put all the engine components back together, start up and check for leaks. Once it has a thumbs up, rear section can be started.

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  16. Drifter

    Drifter Member

    Cat back almost there

    How the heck am I going to keep it that shiny? Look at the last pic, like a snake waiting to pounce on the 1st A4 1.8T it finds [​IMG] (sorry RF, just had to)

    Look at the welds, seamless, just perfect.

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  17. Drifter

    Drifter Member

    Custom double welded Oval silencer

    Still has protective wrapping on it.

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    Custom made 76mm tips with slash cut

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  18. Drifter

    Drifter Member

    Rear section completed

    It is done !!!!


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    Video
     
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  19. Drifter

    Drifter Member



    And that is how we do it in South Africa when the exchange rate sucks.
     
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  20. Cligedy

    Cligedy Active Member

    That is such a good looking exhaust, it seems a shame to wrap it like that. Or hide it under the car for that matter :D
     
    Drifter likes this.
  21. Drifter

    Drifter Member

    I know, every weekend I crawl under the car just to perve. Thanks buddy.
     

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