MustangSteve wrote:

M-U-F-F-L-E-R    S-H-O-P

This is more "fun" and then it turns out the way I want it.
 

I did the same thing with my exhaust, cut-n-weld, it don't look pretty but it works. 

Could you not tac all those pieces together, then take it to a muffler shop that makes custom pipes and have them make two identical pieces?  Then you wont have all the welds in it.  

Just a thought

I'm with Rudi and I also have to say that those welds looks good!

at wrote:

Looks good to me. I just finished doing the same thing. One suggestion, if you ever want to disassemble it, instead of slip joints, get some butt clamps. Jegs and Summit carry them in stainless.

actually the slip joints are going to get welded up.  I plan on putting colectors coming out of the mufflers, just before the pipes go over the differential, so that I can remove the middle section if I need to work on the transmission or somthing else on the car.  That is the one down side to an x pipe if you don't make it easily removable you may find yourself fighting with it down the road.
 

Thanks for all the compliments, I am actually very pleased with it even though I don't sound pleased.  This technique works great, flows great, but its just a pain to do and all the welds (not the quality of but quantity of) could look better. There are gaps in all my but welds so I could grind them all smooth but I don't think I will. I am going to use some 1500º black paint on it once it is all done and that should not only help keep it looking nice but also help protect it.  Fortunately because I am adding collectors after the mufflers I will be able to remove all the pieces for paint.  I will post more pix when I am done painting.

MustangSteve wrote:

I know this is not intended to be a high performance application, so I am hoping "flows great" means it ultimately gets tge exhaust gases out to the rear end of the car.  All those corners surely create a whole lot of turbulence in the flow.  Heck you might not even NEED a muffler!

I do realize and appreciate the amount of work it took to construct that thing!  It is surely harder than it looks.  Have you ever considered purchasing one of those self-contained hydraulic tubing bender like the ones at Harbor Freight?  Seems like that would make it a little easier on you.  Just use a stick of brazing rod to make a template and then bend to match.

 

I appreciate all the nice work too, I have made many a set of exhaust and headers for my race cars. It is a lot like work! I usually end up with something that looks exactly like Daze has. Then the magic begins! If you buy some nice mandrel bends that are smooth you can cut and replace all the sharp bends with smooth ones. I do it all the time. I have a new exhaust going together for the American Sedan Mustang, and it is about to get new smoooooooth elbows to replace all the cut and weld joints that have sharp inside corners. I always do it like Daze did first since the smoooooth elbows are a little expensive. It is easy to cut out the sharp tuns and replace with the smooth ones, it is tougher to get to the point Daze is. I usually re-cut and reweld several of the joints to get to where Daze is. I save the expensive smooth ones till I make it fit. I have never found a muffler shop that can bend some of the complicated twists I need. Good job Daze! I like it!

DC wrote:

I have a new exhaust going together for the American Sedan Mustang, 

 
DC. tell us about this American Sedan Mustang you speak of??

MustangSteve wrote:

I know this is not intended to be a high performance application, so I am hoping "flows great" means it ultimately gets tge exhaust gases out to the rear end of the car.  All those corners surely create a whole lot of turbulence in the flow.  Heck you might not even NEED a muffler!

Seriously???  aw come on "might not even NEED a muffler!" 

None of those joints are very sharp at all, and if you look at them from the inside the transition is fairly smooth.  The two sharpest corners are 45º but they are done with two cuts.



as you can see on the next pic the inside transition is nice



are they going to flow as well as mandril bends, probably not but the only time a person would really notice is if they were running a much bigger engine with a much higher RPM range.   I think with the PERFORMANCE 302 this exhaust is going to atach to this system is a far better flowing exhaust than the engine is ever going to need. 

MustangSteve wrote:

Have you ever considered purchasing one of those self-contained hydraulic tubing bender like the ones at Harbor Freight?  Seems like that would make it a little easier on you.  Just use a stick of brazing rod to make a template and then bend to match.

Ya they suck.  They kink pipe rather then bending it unless you fill the tubing full of sand and cap it off at both ends.

terry wrote:

DC wrote:

I have a new exhaust going together for the American Sedan Mustang, 

 
DC. tell us about this American Sedan Mustang you speak of??

 My AS Mustang hard on the brakes at Nelson Ledges!

I used to spend a lot of time on the flow bench and discovered that if you keep the inside turn radius close to a quarter of the tube diameter you get respectable flow. If you go below a seventh of the diameter you loose big. FYI

DC wrote:

I used to spend a lot of time on the flow bench and discovered that if you keep the inside turn radius close to a quarter of the tube diameter you get respectable flow. If you go below a seventh of the diameter you loose big. FYI

DC I'm a little slow, could you put what you said into numbers?  I think you're saying if you have a 2" pipe the inside radius of the bend should be around 1/2"?  I think I'm misinterpreting something.