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Old 10-03-2012, 10:08 AM   #1
SENZA PARI
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Default Senza Pari Custom Exhaust Manifold

We do enough custom manifolds for other set-ups, yet I haven't done one for my own daily driver just yet. This will be going in my Forester... it will have a V-band outlet which will mate up with the rest of the custom exhaust, which will follow shortly.
Designed first in SolidWorks, and laser-cut so everything fits up perfectly. Debting on whethere to Electro-polish it or leaves the welds raw... we'll see how it looks once it's finished.


Untitled by SENZA PARI #1, on Flickr


Untitled by SENZA PARI #1, on Flickr


Untitled by SENZA PARI #1, on Flickr


Untitled by SENZA PARI #1, on Flickr
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Last edited by SENZA PARI; 10-12-2012 at 01:20 AM.
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Old 10-03-2012, 06:01 PM   #2
TURBOTOD
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Huge fan... Can't wait to see final product and rest of exhaust, as well as numbers.
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Old 10-03-2012, 08:09 PM   #3
STiFab4
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Looks great man!..leave the welds raw
and what grade stainless is that?..just curious.
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Old 10-03-2012, 08:58 PM   #4
SENZA PARI
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Thanks for the kind words. Material is 304ss. More to come tomorrow!
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Old 10-03-2012, 09:24 PM   #5
subyswamper
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I like it. A little different just visually which is cool.
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Old 10-04-2012, 09:46 AM   #6
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Wow that looks fantastic!
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Old 10-05-2012, 08:34 PM   #7
STiFab4
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Quote:
Originally Posted by SENZA PARI View Post
Thanks for the kind words. Material is 304ss. More to come tomorrow!
thought so,i could'nt tell really if it was 304 or if you went with 321..
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Old 10-07-2012, 12:00 PM   #8
2006whitesti
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Looks good so far, but man that thing looks like it is going to hang pretty darn low.
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Old 10-07-2012, 12:26 PM   #9
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subscribed for the results. It does look like it might be a little low...
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Old 10-07-2012, 04:25 PM   #10
SENZA PARI
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This picture isnt the best, but the old manifold collected well in front of the subframe, and then dips down below it. The new manifold collects further back, so there isn't room to dip down. Instead, the new manifold is designed to put the collector outlet at the height it needs to be at to clear under the subframe. So although the initial height of the runners is a bit more, the new manifold doesn't give up any clearance over the old one.


002 by SENZA PARI #1, on Flickr

Runner 1 and 2 complete:


Untitled by SENZA PARI #1, on Flickr

It should be finished up in the next day or two, then onto the rest of the exhaust. The muffler openings in the stock Forester rear bumper will be filled with our own 4" mufflers, with turn-down pie-cut tips just like our downpipes:


IMAG0195 by SENZA PARI #1, on Flickr

IMAG0175 by SENZA PARI #1, on Flickr
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Old 10-07-2012, 08:33 PM   #11
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Wow you really enjoy using argon. I wish I had half the skills of yours.
I have a question though. Why do you prefer pie cuts to mandrel bends? I've seen your work on other sites and noticed that you prefer the pie cuts. Is it to show off the welding skill? Also, are you using Solar Flux on some parts? It doesn't look like it to me, as the welds are pretty (and without the crap floating to the top) or do you only purge some of the welds? I would assume with that many welds, you must eat through argon pretty fast if everything is purged.

Just curious.
I tried using Solar Flux on a downpipe, and noticed that the residue can float up and not just on the inside of the pipe. Or am I doing it wrong?

Awesome work
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Old 10-07-2012, 09:52 PM   #12
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No slip fit between banks? Aren't you worried about cracking?
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Old 10-08-2012, 11:08 AM   #13
wantsti
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wow amazing quality
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Old 10-08-2012, 11:48 AM   #14
SENZA PARI
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Thanks for the kind words.

Quote:
Originally Posted by reid-o View Post
Wow you really enjoy using argon. I wish I had half the skills of yours.
I have a question though. Why do you prefer pie cuts to mandrel bends? I've seen your work on other sites and noticed that you prefer the pie cuts. Is it to show off the welding skill? Also, are you using Solar Flux on some parts? It doesn't look like it to me, as the welds are pretty (and without the crap floating to the top) or do you only purge some of the welds? I would assume with that many welds, you must eat through argon pretty fast if everything is purged.

Just curious.
I tried using Solar Flux on a downpipe, and noticed that the residue can float up and not just on the inside of the pipe. Or am I doing it wrong?

Awesome work
We did a few parts using pie-cuts last year simply for the fun of it, as we've always liked the way its looked. After that, customers started asking for it. It's kind of become our trademark now.
One advantage the pie-cuts do have is they make fitting up complex bends much easier than cutting bends down to the correct angle, as they're a known angle and can be indexed as needed.

We haven't used Solar Flux, just alot of brushing and prepping to keep everything clean.

Quote:
Originally Posted by indytruckboy View Post
No slip fit between banks? Aren't you worried about cracking?
One of the first things I did with the old manifold is weld up the slip-fit connection, as it was the source of an annoying buzz at certain rpm. I've taken the manifold on and off numerous times and there hasn't been any warping. Given the costruction of the old manifold (chinese garbage) vs the new manifold, it will outast the car and then some.
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Old 10-08-2012, 01:14 PM   #15
I--RIDE--BIKES
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Great looking products. If you aren't using solar flux, are you back purging to prevent sugaring on the inside of the weld?
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Old 10-08-2012, 01:24 PM   #16
SENZA PARI
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Quote:
Originally Posted by I--RIDE--BIKES View Post
Great looking products. If you aren't using solar flux, are you back purging to prevent sugaring on the inside of the weld?
Thanks. Correct, everything is purged.
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Old 10-10-2012, 01:08 PM   #17
SENZA PARI
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Last runner...


Untitled by SENZA PARI #1, on Flickr
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Old 10-10-2012, 04:55 PM   #18
STiFab4
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Quote:
Originally Posted by SENZA PARI View Post
Last runner...


Untitled by SENZA PARI #1, on Flickr
looking good as hell.
..random props for not using flex head torch,keepin it og.

also do you pulse??
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Old 10-11-2012, 03:05 AM   #19
TURBOTOD
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Quote:
Originally Posted by SENZA PARI View Post
^ Holy Crap! When I do my rotated setup, will you do a DP like this for me? I want it. It's fantastic.

Peace-
TurboTod
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Old 10-11-2012, 03:33 PM   #20
SENZA PARI
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Quote:
Originally Posted by STiFab4 View Post
looking good as hell.
..random props for not using flex head torch,keepin it og.

also do you pulse??
We do pulse on most parts... saves a considerable amount of time with cool-down, amongst other benefits.

Quote:
Originally Posted by TURBOTOD View Post
^ Holy Crap! When I do my rotated setup, will you do a DP like this for me? I want it. It's fantastic.

Peace-
TurboTod
We absolutely could! You know where to find me:-)


... more photos of the manifold to come tonight, just about complete.
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Old 10-11-2012, 08:53 PM   #21
SENZA PARI
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Untitled by SENZA PARI #1, on Flickr


Untitled by SENZA PARI #1, on Flickr


Untitled by SENZA PARI #1, on Flickr


Untitled by SENZA PARI #1, on Flickr

And a little of the rest, starting with our own mufflers.


Untitled by SENZA PARI #1, on Flickr


Untitled by SENZA PARI #1, on Flickr


Untitled by SENZA PARI #1, on Flickr

More to come.....
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Old 10-11-2012, 10:22 PM   #22
Crazy_pilot
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Amazing work. I want a TIG now.

Question: Do you ever end up with sunburnt hands after welding a lot? I did 6 or so hours of MIG work on a school project a while back wearing a t-shirt and had noticeable sunburns on my arms after.
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Old 10-15-2012, 08:42 PM   #23
norexyet
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Looks awesome!!

6 straight hours of mig welding without sleeves or gloves is mayhem. When i use a tig i rarely use gloves though, something i need to stop doing.
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Old 10-15-2012, 11:00 PM   #24
subyswamper
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Pm me a price of what a header like that would cost to buy?
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Old 10-16-2012, 12:08 AM   #25
SENZA PARI
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Default Exhaust manifold

Thank you for the kind words.
Yes, welding for hours straight will result in sun burn! We typically wear full sleeves... but no gloves. Hands usually stay fine, although I do have a tendency to always grab scorching hot parts. You think you'd learn...

subyswamper, I'll send you a pm this afternoon.

Last edited by SENZA PARI; 10-16-2012 at 12:06 PM.
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