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 Write-Up: Custom Y-Split Exhaust Pipes

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Karma
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PostSubject: Write-Up: Custom Y-Split Exhaust Pipes   Wed Jul 14, 2010 11:32 am

I've got a bunch of pics, and some custom work, so this is in its own thread.
I'll fire a link to here from "The Muffler Thread" too.

So, when spending money like a drunken sailor on car stuff, I all of a sudden decided to do exhaust work too. I was looking around for what mufflers I'd like and stumbled across this:
http://www.dynomax.com/mufflers.php?muffler=vt

It was newish, and seemed like a neat gimmick. So I started researching. Every thread for every auto forum on the Internet was similar. Next to no sound clips. People agreed it was a cool idea. Biggest fear was a failure of the return spring, or rattling. But, I thought, "Its Dynomax! lifetime warranty!" So on a whim, I bought 2 in 2.25 size.

Fast Forward to 2 days before my sister's wedding. My car was going to be driving around the wedding party along with the wife's 98 riv. I was scrambling to get everything I wanted to on it done, and naturally, I was ambitious...So I cut the back off my exhaust system:



Now, since I was in a hurry, there are not pics of the entire process, but here is what I have.

The mufflers box:


I mocked things up based on the shape of the stock bit I had cut off.


I only had the following to work with:
2 X 2.25 dynomax VT mufflers
2 X Magnaflow weld on tips
2 X 2.25 mandral bent U bends
2 X universal exhaust hangers
1 X 2.5 ID to 2.75 OD connector

I was *hoping* I could make a workable exhaust in 2 days, with minimal parts, no experience, and one mess up I would be SOL.

From mocking up things on the floor, I found the angle that I wanted for the Y pipe to be 42 degrees from center. If I had known this before, I could have bought a Y pipe that was the same or very close and saved myself a ton of work.

The plan was to split into the Y a tiny bit back from where the stock on was, into the two mufflers on angles to clear the spare tire "dip", then turn back the 42 degrees to go straight out at the stock exhaust locations with tips.

Now I had only 2 U bends to work with. And each cut had to be right. So the theory was to cut the U in half, mark out the angle at the end bend part of each piece, cut it perfect, do the same in the other piece, weld together, cut the mid point square, and weld on a straight bit to slide onto the stock 2.5" pipe. Things were slowly sinking in as to what I had ahead of me.

And so, I went forwards the only way I know how. With absolute precision! I would cut the angles in the milling machine:






Which worked surprisingly well. I fired some bits of Delrin into the pipe so it couldn't crush or distort in the mill.

Then marked out the other piece:


And cut it too.

I pipe clamped them together for some more mock up:


Then got "the expert" ,my dad, to TIG them. I can MIG ok, but I'm still learning TIG, and I had no room for error here.




The back end was cut square with a little to slip the straight piece on:


And welded:

The welds are ok, but not the norm for dad. It was my fault cause I forgot to clean the oil off them before declaring them ready for welding. Anyone who has welded knows what oil contamination does...

Some pics are missing, but basically there was alot of screwing around to decide the angle of the mufflers, and lots of dry fitting. I have new respect for exhaust shops who can make everything right, and not look like a crooked bag of crap.

The finished bit:


More fitting on car, and figuring out the hang points:








Then masked off and painted with black header paint. I wanted the piping to not draw any attention to itself under the car so it would look like it belongs.



Hangers:
The bolts for the rear bumper mount are perfect location for easy hanging with universal exhaust hangers:




And finished:




I wanted them *just* flush with the back of the car, and went with rolled edge, oval, slant cut, Magnaflow tips. Something "subtlety showy"

I'm very pleased with the result. Dynomax is right, there is NO drone at all. Its as quiet as stock, with a very slight rumble at idle. Highway cruising is quiet. I'm told that at WOT, when the valves open, it sounds pretty aggressive, but I can't hear it over the scream of the supercharger anyway. I'll get vids up whenever I can find a chance.





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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Wed Jul 14, 2010 11:42 am

Fantastic work!

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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Wed Jul 14, 2010 12:18 pm

nice work, looks kinda like mine minus the huge tips/glasspacks lol

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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Wed Jul 14, 2010 12:35 pm

Very nice fabrication job. A+ clap
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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Wed Jul 14, 2010 1:45 pm

That's what I have been waiting for 3 or more years to hear.
Someone finally made a muffler that will work without droan at cruise yet open up under heavy throttle.
And naturally, someone else trying them out first is a big bonus.

Thanks a lot Karma, can't wait for the video and audio clip of them.

Rick
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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Wed Jul 14, 2010 3:16 pm

Nice setup! Those DynoMax VT's are my next investment. The SuperTurbo's just didn't last. The driver side muffler is starting to peel apart!
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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Fri Jul 16, 2010 8:37 pm

That's a beautiful fabrication job. Really looking forward to an audio/video clip as well. Hats off
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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Fri Jul 16, 2010 10:06 pm

I second that,very nice work... 3gears
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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Fri Jul 16, 2010 10:12 pm

Andrew, I wish I could do what you do.
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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Sat Jul 17, 2010 2:56 am

I love the way the new tips almost perfectly match the originals, just on a smaller scale...
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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Sat Jul 17, 2010 3:09 am

super work! wow! cant wait for the sound clips!
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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Wed Sep 15, 2010 2:11 am

Karma,
Have you had the time to do any sound clips of the VT's and do you have any new info on them as far as use and the possible issue with the internal springs.
Any internal rattles, etc.

How about a semi- long term follow up with sounds.

I want to do this if you suggest the mufflers are holding up well. Would like to get it done before the winter snow starts falling.

What say you.?????
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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Wed Sep 15, 2010 8:15 am

So far, I love them. No rattles or anything. Mellow rumble, just a tiny bit louder than stock. WOT, I have not a clue since the SC sounds like a cat in a blender. The only thing that has cropped up since they have "broken in" is that there is the *slightest* tiny blip of drone at 2000rpm, like I have to work at making it happen. If the rpm changes by even 2, its gone again. Longer res might take that right out of the system, since I'm still using stock.

I'll try and get some sound-clips this weekend, since my brother is coming up and can bring his camera.

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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Tue Sep 28, 2010 9:37 pm

sound clips?
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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Fri Oct 08, 2010 1:59 pm

Karma,
Do you know if the stock diameter pipe going into the stock muffler is 2 1/4" on the 1998, I can't remember anymore, it's been so long since I did the Headers and HF Cat. I measured everything at that time.?

Did you buy Dynomax P/N 17155 mufflers, which are the 2 1/4" offset inlet and center outlet for Dual exhaust.

For some reason they list a different P/N for a VT Muffler that has the same inlet and outlet diameter yet designed for a single muffler system up to 4.0 Liter engine.

Or do you think I should increase the pipe size from where you cut it to a 2 1/2".
Then have the Y and the pipes custom bent to the mufflers at 2 1/2".

Wondering what your thoughts are on this.

Would like to buy 2 of these mufflers next month and bring them to the custom shop and have the work done.

I intend on leaving the stock resonator in the car. Once all this other work is done, it will be the only stock piece left in the exhaust system.

BTW, the new exhaust tips I bought have an inlet size slightly larger than 2 1/4" by about 1/8". Just throwing that out there, as any size pipe can be made to fit them with adapters if necessary.
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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Fri Oct 08, 2010 2:28 pm

I know my name isn't Karma. Although I'm sure the exhaust system on a stock 98 is the same as that of the 95, the only difference was before the cat. I remember looking at both when I did mine earlier this year. The stock exhaust was pretty anemic on the Riviera at 2 1/4 cat back into 1 7/8 Y to the mufflers. Double check the thread I put up on "Max exhaust size for 95 Riviera SC" all the pertanant info for sizing should be on there.

Hope that answer part of your question. canada

Or you can view the info on walkers webpage here: http://www.walkerexhaust.com/catalog/vehicletypescrnexhaust.asp
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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Fri Oct 08, 2010 2:48 pm

Thanks for the info and the Link.

That was exactly what I was looking for.

I can weld a new Y at 2 1/4" to match the center pipe and add 2 - 2 1/4" inlet mufflers for a decent exhaust.

Not going for loud and don't mind leaving a few horsepower on the table either. I want to try the Variable Tune DynoMax Mufflers. Shouldn't cost me much more to finish off the exhaust system by cutting before the factory Y and starting from there to the end of the tips.
I'll just keep it all at 2 1/4" from that point back. Weld some stainless pipe with stainless mufflers and Tips.
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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Fri Oct 08, 2010 2:58 pm

No problemo Ricky Bobby! SHAKE AND BAKE!!! happy
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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Fri Oct 08, 2010 10:40 pm

Ricky Bobby - Shake and Bake.. Friggin hilarious.

The one good thing about exhaust is you can always change it quite easily if you don't like it.

By the way, never did see the movie. It's probably available on my cable system for about a buck by now. I'll have to watch it.
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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Sat Oct 09, 2010 5:41 pm

Wow, nice info and diagram... I think they took this from the Factory body manual. thumbsup
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PostSubject: Re: Write-Up: Custom Y-Split Exhaust Pipes   Mon Oct 18, 2010 9:23 am


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