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Old 09-15-2010, 01:00 PM   #1
drifte
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Default TAB Fabrication builds Subaru Aluminum v-band exhaust

TAB Fab known for building their Evo aluminum exhaust systems used my Forester and came up with an exhaust. Including the down pipe(which is stainless) my entire exhaust probably weighs less than the stock muffler. V-band off the down pipe to about 6ft of straight 3" aluminum with a slight bend after the rear diff to a straight through custom aluminum muffler. Vibrant makes aluminum mufflers but this was built in house by TAB. Car sounds mean, dont have any drive by's of it yet though. They put this together in just a few hours and it hasnt been cleaned up or anything yet. Need to shine it up yet.

On to the pics:


STI cat back off

This is about all it needs




Car still retains a small catalytic converter before the turbo, needs some tuning real bad to. With this straight through exhaust you constantly just hear the turbo screaming out the back. ..it's great. Its tucked clear up in their, its amazing how well its fit for only a few hours work. And it weighs maybe 6 lbs.


And a quick rev (I live in a quiet neighbor hood and it was like 7am):

-Colton
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Last edited by drifte; 09-15-2010 at 01:20 PM.
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Old 09-15-2010, 01:15 PM   #2
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You have an aluminum downpipe? That sure isn't going to hold up.
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Old 09-15-2010, 01:20 PM   #3
drifte
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Down Pipe is stainless. I'll edit that in.
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Old 09-15-2010, 02:18 PM   #4
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Very interested in undercar shots and sound clips.
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Old 09-15-2010, 02:41 PM   #5
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Heres a pretty bad phone pic. Will take it off the car tonight (its so easy!) and get pics.

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Old 09-17-2010, 01:44 PM   #6
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nice, can you give us an idea of what the total price for it was? thanks...
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Old 09-17-2010, 06:28 PM   #7
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Interesting. I wonder how it Al compares to Ti and SS in cost, weight, and durability?
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Old 09-18-2010, 06:36 AM   #8
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Al is 40% the weight of steel and Ti 60%. Al is not nearly as strong and Ti is comparable. Al tube is cheap while Ti is quite expensive, "if you have to ask" expensive. While Al isn't as durable to exhaust temps, it'll probably be okay post downpipe.
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Old 09-18-2010, 12:11 PM   #9
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These pics suck...... we need to see some details!!!!

kthx!
Jay
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Old 09-18-2010, 01:04 PM   #10
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Quote:
Originally Posted by stidoc View Post
Al is 40% the weight of steel and Ti 60%. Al is not nearly as strong and Ti is comparable. Al tube is cheap while Ti is quite expensive, "if you have to ask" expensive. While Al isn't as durable to exhaust temps, it'll probably be okay post downpipe.
You have to do better than that. I'm a mechanical engineer who has worked in both a Ti and an Al foundry.

I'm not an exhaust system designer, but this dumb engineer knows it is more than the density of alloy and the yield strength when very warm. Wall thickness influences weight and strength too. Thermal fatigue and expansion are another two things I can think of.

There must be a reason why cat back Al systems haven't caught on. Could it be fabrication cost?

FYI: Ti is much better than SS at elevated temperatures for both strength, thermal fatigue and corrosion. Inconel and Hastalloy are even better, but even more costly in material, weldablity, and machining.

I learned about machinablity about 26 years ago on some weld test coupons. The Hard Way...
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Old 09-19-2010, 06:33 PM   #11
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You might want to take a look at this article:

http://www.burnsstainless.com/yieldstrength.aspx
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Old 09-19-2010, 07:44 PM   #12
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Meh, it's an exhaust. I'm sure it will be fine. I'd worry about the interface between the stainless and the aluminum, and it's probably going to move around like crazy as it heats and cools, but it'll probably be fine. Won't survive a knock - if you get a good dent in it it will probably crack.

*shrug*
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Old 09-19-2010, 08:29 PM   #13
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Quote:
Originally Posted by wheatpaste View Post
You might want to take a look at this article:

http://www.burnsstainless.com/yieldstrength.aspx
Interesting find. It does explain why the market isn't flooded with Al cat backs. Very niche market part. An Al muffler might still be a good deal though as it is bigger, heaver, and cooler.

Quote:
Originally Posted by sniper1rfa View Post
Meh, it's an exhaust. I'm sure it will be fine. I'd worry about the interface between the stainless and the aluminum, and it's probably going to move around like crazy as it heats and cools, but it'll probably be fine. Won't survive a knock - if you get a good dent in it it will probably crack.

*shrug*
I'm fairly sure the Al would bend before it would break. It just wouldn't take much to crush it.

Edit: I may have to retract that last bit. If the tube is 6061 and is up around 400 deg F for hours it will age and get hard to the point where an impact could crack it.

Last edited by Web Foot STi; 09-20-2010 at 01:41 PM.
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Old 09-20-2010, 12:10 PM   #14
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Sorry I havent updated with some legit pics and vid. Busy weekend. TAB has taken the steps to insure the product will last and hold up, I'm not even conserned in that aspect. I look at in cost to performance, it cant be beat imo.

forgot, as far as price goes you'll have to contact them as setups can vary, tab-fabrication.com.

I hate gaskets so v-band was the only way if you ask me.

Last edited by drifte; 09-20-2010 at 12:16 PM.
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Old 09-20-2010, 12:31 PM   #15
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Just spoke with Trevor of TAB, he said he could do a typical wrx setup for $450 SHIPPED. That system would include a ss v-band flange to have locally welded to your Downpipe, and utilize a single aluminum muffler. I have a link to the muffler used here:
http://vibrantperformance.com/catalo...oducts_id=1704
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Old 09-20-2010, 03:40 PM   #16
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What's the wall thickness on the AL tubing? Oversized for a little more longevity?

I gave this some thought years ago and have been looking to revisit the idea again.
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Old 09-20-2010, 04:11 PM   #17
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16 gauge. Check out their website, some of these exhaust systems have gone through snow and salt and thousands of miles already.
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Old 09-22-2010, 07:33 AM   #18
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Quote:
Originally Posted by Web Foot STi View Post

FYI: Ti is much better than SS at elevated temperatures for both strength, thermal fatigue and corrosion. Inconel and Hastalloy are even better, but even more costly in material, weldablity, and machining.
Titanium can only be used below 1200*F, or sustained below 800*F, as the structure changes and it begins to degrade, literally fall apart. That's with the "pure" CP grades. Aluminum/vanadium Ti alloys are much more temp resistant but ghastly expensive and hard to machine. It is used by NASA and Bugatti. So while Ti in most cases will be fine for post downpipe exhaust applications, you cannot use it before then. Aluminum isn't widely used as its just not durable. If the OP is willing to change his out after 3-4 years, no problem, but OEM can't use it.

Cobb used to sell an Inconel uppipe for a short time but I guess it was too expensive. Even 321 is probably going to be too expensive in all but racing and one-off applications.
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Old 09-22-2010, 09:27 AM   #19
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Yup.

Ti is great in the cold section of a jet engine, or a turbo, but does not cut the grade on the hot side. We cast 6/4. The other side of the place cast hot section parts.
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Old 09-23-2010, 05:41 PM   #20
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Quote:
Originally Posted by Web Foot STi View Post
Edit: I may have to retract that last bit. If the tube is 6061 and is up around 400 deg F for hours it will age and get hard to the point where an impact could crack it.

Well, i meant that it would crack due to the thermal cycling and stress risers/compromised material near the dent. But that too.
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