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Old 02-26-2012, 11:24 AM   #1
EJ20DK
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Default EJ22 Full Exhaust Project

Hey NASIOC,
I'm building a little project car it's a 92 Leggy Wagon with a N/A EJ22 (For Now ) I want to build a COMPLETE exhaust for it from heads to tips. I have 2 priorities for this exhaust build, 1. Must sound like SEX! and 2. Must look like SEX! hehe Second part will be a little difficult as I'm not the most experienced TIG welder... Anyways, I'm planning on it being a Stainless/Aluminum Exhaust. Full Stainless header v-banded to an aluminum dual side exit setup. I'll be using one Borla muffler and no cat. I'm literally just in the starting stages of this so I only have a couple pics to share, but hopefully I will have updates every couple days or so and plenty pics to go with them. Any input will be greatly appreciated! Thanks!



Here I've got some flanges I got my waterjet guy to cut up for me. All are 1/2" SS304 . I guess the only one that applies to this build is the dual port manifold flange...


Here I just started tacking up one of the primaries...


MOAR Tacked Up Primaries!


That's all for now but I will update as often as I get some work done...
Oh yea the rust bucket it will be going on for the hell of it...


Let me know what ya think!
- Martin
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Old 02-26-2012, 05:47 PM   #2
wantsti
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Looking forward to the finished product.
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Old 02-27-2012, 12:03 AM   #3
EJ20DK
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Well, That makes the two of us!

I actually had a bit of time today to TIG up the primaries...
Let me know what ya think.







Now comes the difficult part I'm guessing of making the merge collector pieces...
- Martin
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Old 03-01-2012, 12:20 PM   #4
EJ20DK
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I've had a little more time in the last couple days to get a little more work done, snapped a few pics and so here they are! Any input is much appreciated!



















My dog likes shiny things


Let me know what you think...
-Martin
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Old 03-01-2012, 08:18 PM   #5
syndromeofthedown
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Only feed back I can give you is make your ripples closer together(strictly an appearance thing) and make sure that if you're welding on ANY of the water jet cut surfaces on the flanges clean that surface off. The garnet used in the water jet cutting may affect how it welds. Other than that, looks VERY nice. Great color in your heat affected zone and from what I can see in your pics nice purge.
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Old 03-02-2012, 04:10 PM   #6
EJ20DK
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Thank You! I'll definitely try to keep the bead a little tighter. Also I always try to acetone the crap out of any welding surface as I remember I left a little sharpie on something aluminum I was welding and it just went to complete ****... Good to know about the waterjet parts having some left over residue that may affect the weld itself, I'll be that much more anal about cleaning the crap out of them also before I weld my primaries to them. Hopefully I will have a little time tonight and tomorrow to do get some more progress on the project.
- Martin
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Old 03-04-2012, 12:39 AM   #7
AREA1320
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Y u no use filler??
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Old 03-04-2012, 12:39 PM   #8
EJ20DK
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If I'm butt welding up 16 gauge pipe and the fitment is PERFECT then I use VERY Little to no filler, I just don't think its necessary unless it was a big structural issue... Some turbo applications I would treat a little differently however.

I managed to get a little more done over the couple days, so I will share some of my progress. Any input much appreciated!















- Martin
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Old 03-04-2012, 01:35 PM   #9
wantsti
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It looks so good!
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Old 03-05-2012, 12:53 AM   #10
EJ20DK
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Thank you sir! I hope it sounds it too!
-Martin
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Old 03-06-2012, 09:46 AM   #11
DriftMonkey2JZ
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Martin,
That is some mighty fine TIG welding! I haven't had the chance to try TIG welding, but it looks like an art! Keep up the great work. Subscribed
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Old 03-06-2012, 11:31 AM   #12
Storm
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Absolutely incredible quality!

Jay
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Old 03-07-2012, 12:53 AM   #13
EJ20DK
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Thank you very much for all the kind words guys! I really appreciate it! I will try to get some work done on it here soon, I've been super busy with a few other things... Thanks again for the compliments!
- Martin
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Old 03-07-2012, 09:26 PM   #14
Keif
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Looks like you know what you're doing.


I've never seen "pie cut" primaries before.
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Old 03-08-2012, 02:07 AM   #15
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Looks amazing!!
I wish I had access to the tooling and materials to do this kind of work, and to refine my welding skills.

Keep up the great work!
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Old 03-10-2012, 11:54 AM   #16
EJ20DK
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Thanks again for the compliments! I'm glad you guys like my work! I really enjoy making stuff like this, anything motorsports, auto moding related... Hope this kinda gets my name out there, I'll start another thread with some other stuff I've made hopefully you will like some of that stuff also.
Anywho, I had more time to get a little further along in the project so on with the progress pictures!




All cleaned up from the inside...

Chopping stuff up, also you can see how the pipe comes on the left and after I polish it (satin, not mirror polish) on the right














Any comments much appreciated! Thanks!
- Martin
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Old 03-10-2012, 02:58 PM   #17
Subikid90
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Nice work!

What do you use to cut all of your pipes?
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Old 03-10-2012, 08:26 PM   #18
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Quote:
I'm not very experienced with welding but it doesn't look like you're getting any penetration here.



The look amazing all polished up.

Last edited by Keif; 03-10-2012 at 10:39 PM.
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Old 03-10-2012, 10:32 PM   #19
az02wrx
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you better post a vid of how these sound when you are done. please lol
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Old 03-11-2012, 10:29 AM   #20
syndromeofthedown
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Quote:
Originally Posted by keithwrx8 View Post
I'm not very experienced with welding but it doesn't look like you're getting any penetration here.



The look amazing all polished up.
There's way more than enough penetration on this joint. In any case of welding if the weld is properly fused to the thicker member as well as the thinner member, in this case the tubing, the penetration is fine. It's totally not FULL penetration but certainly enough to not crack and to last the lifetime of this exhaust.
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Old 03-11-2012, 01:10 PM   #21
Keif
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Are you talking about the welds on the flange? I'm talking about the welds in the tubing/primaries.
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Old 03-11-2012, 01:21 PM   #22
tibug
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WOW! That's a lot of work for that rust bucket...but that's good. Way to go.
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Old 03-11-2012, 02:22 PM   #23
seanathanq83
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how are you going about cutting the pipes??? also not sure if you posted and i didnt see it but what type of tubing are you using??
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Old 03-11-2012, 05:33 PM   #24
EJ20DK
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Thank you very much for the compliments guys! Much appreciated!
To answer some questions...

Unfortunately I'm using just a chop saw to cut the pipe, so yes its very tedious to get it all deburred and perfect afterwards. I use a 3M EXL wheel on the bench grinder to get them nice and to polish them satin also... I use a bandsaw to cut where I do my pipe merges.


Piping used is 304ss Primaries are 1.87 they merge into 2.25 which will merge to 2.5 ultimately. Yes, I know it is pretty big. The I.D. of the primaries will match my ported heads though perfectly... All piping is 16g.

Have no fear, videos of the finished product in action are a certainty! I can't wait myself!!! Also, the youtube.com link under my screen name on the left has a couple of vids of the very first exhaust I ever made literally the day i could TIG weld. Doesn't sound too bad

I hope there is enough penetration on the primaries... I weld all my 16g pipes at the same amperage unless of course its to a flange, then it gets more juice But I guess the test of time will tell if that is true..

Too much work for the rust bucket? naaaah! I love doing it so its all good fun and practice. Besides I know it doesn't look it but its pretty built up... Soon to be STI drivetrain and nice EJ22T hybrid so it will be a baaaad lil sleeper beast!

Here are a few pics also of the matching intake i made for it a lil while back...
Hope you like it.







Enjoy.
- Martin
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Old 03-12-2012, 11:23 AM   #25
08mendozasti
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Look Awesome!
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