New Custom Exhaust Single Exit 3.5''
 

For the past 3 weeks I've been working in my basement on my Version 2 of Megan's Exhaust.

After about 60 hours of work I finally got it done ! :cool:
Basicaly the setup is;
Modular Y-Pipe setup with the choice of either 2x Resonator or 2x HFC
Y-Pipe include a transition edit: Deleted Secret matterand a megaphone of edit: Deleted Secret matterto 3.5''OD
The Mid-Pipe include a big 3.5'' Resonator
The Muffler is a straight flow.
Using only V-Bands ( then machined by me at work.)


EDIT;
Some peoples request a Fly-by video !
Here it is as requested.

Yeah its dark, but who care ? the noise is still noise ! :)
Video took from a GoPro HD




It is very loud by 3500rpm, in the video 0;56 to 1;06 mark, it is where I was shifting at 3500rpm.
Cruising at 80km/h (50mph) the exhaust is actually very quiet which I was quite surprised ! but anything higher than 65mph will require a bit more voice strength if you want to keep a conversation with your passenger.




This is using the shorty Momentum header, there was a plan in the beginning to modify it right at the collector but I decided to ditch that idea because of a future plan.
But the planned transition was still used on the exit flange.


Everything started about 2 months ago when I was thinking what I should do about the exhaust problem since my previous one was just a prototype and was too heavy.

The idea has been fixed for a Single exit that would be using the center exit on the OEM bumper. Since there will be a flat underbody & diffuser made, this was the smarter way to do it properly.

So let start with the beginning when I received the parts !

Part Order # 1
Mandrel U-Bent in 2.5'' & 3.5'' ... V-Band . resonator/HFC/muffler

http://www.the370z.com/members/megan...821-184539.jpg


Part Order # 2 (From burnsstainless.com)
Some transition & megaphone
Then the V-Bands that I received from Order #1 which I machined at work for an optimum flow.

http://www.the370z.com/members/megan...nce-effect.jpg


This is the first part that I started working on , the Y-Pipe.
The goal was to find the right angle cutting setup using an online software.

http://www.the370z.com/members/megan...g-vs-30deg.jpg


The Result of it ?
This, forgive me if one side is longer than the other, it didn't matter.

http://www.the370z.com/members/megan...825-191936.jpg

http://www.the370z.com/members/megan...825-192003.jpg


Then once I cut both Transition & Megaphone as what my plan was it ended to be 1/8'' off in length but this was due to the V-band ! so I successfully made exactly what was planned on paper !
14 1/8'' Long

http://www.the370z.com/members/megan...-first-one.jpg


Once the center piece of the Y-Pipe was completed I started to work on the headers & Shorty Test Pipe.
You can see that I welded the transition directly on the flange

http://www.the370z.com/members/megan...-test-pipe.jpg


This is how it look on my spare engine. !

http://www.the370z.com/members/megan...vel-engine.jpg

The next step was to make the modular part of the exhaust, similar to what Motordyne does with their XYZ Y-Pipe
But this one is before the actual Y-Pipe section.
You can see my clearance guide ;) (aka the coat hanger )

http://www.the370z.com/members/megan...river-side.jpg


Once completed !
From top to bottom
-Modified Momentum header + shorty test pipe & modular resonator
-OEM Header & Cats
-PPE Step header

http://www.the370z.com/members/megan...-test-pipe.jpg


So of course I had to test it on the car itself to make sure everything was spot on for both side with the best ground clearance possible I actually gained about 1/2'' of ground clearance over the PPE.

http://www.the370z.com/members/megan...tig-welded.jpg

http://www.the370z.com/members/megan...tig-welded.jpg


Now, I was back to the Y-Pipe section.
This is to show the difference between;
-OEM Y-Pipe
-my 2010 custom X-Pipe (has a shorter flow path than OEM !)
-Future Y-Pipe configuration (an even shorter flow path than previously )
The resonator are actually facing toward the Y-Pipe to help with the flow path but I was restrained by the actual transmission support bracket.

http://www.the370z.com/members/megan...han-x-pipe.jpg


So Y-Pipe ver.1 did not work correctly due to an unforeseen clearance issue with the driving shaft, the next idea was to modify a couple bent to have it off-centre going toward the passenger side (corner balance in mind...)
a few hours later this is what the project came down.

http://www.the370z.com/members/megan...907-121955.jpg


A closer look at the Y-Pipe.
Keep in mind that the last time I welded Stainless was back in school 10-12 years ago and 7 years ago as a welder before joining the Army. I got my first welding machine in May 2013 which is a AC/DC Tig welder. ! :)
After a few practice weld I was ready to go on the real thing !

http://www.the370z.com/members/megan...907-122010.jpg


At this point I was now gonna need the Z on 4 jack stands for the rest of the exhaust.
For those who does follow my Journal knows that I talked about removing the rear tower sub-frame brace to make something similar like the 350z.
During a prior inspection and evaluation of my project, I discovered that our 370z share a very similar underbody bolt pattern and it appear that we could most likely use the bracket that I am looking for .
Unfortunately my closest Nissan dealership fail to find that bracket in their system so I had to think about something else which finally ended to be something very easy to do ! Yeah me.


This picture show the difference between the 350z & the 370z
There is 2 pre-threaded nut into the 370z frame where on the 350z is it used for the bracket that I was looking for.
http://www.the370z.com/members/megan...350z-under.jpg

This is what I made.
Sorry about the baby blue color but its the closest thing I had here . ;(
The 2 outer nuts are just there as a spacer since I didn't had the right length of bolts and didn't want to cut them. then the 2 middle bolts are welded at the bottom and the nuts on them are also there as a spacer then the 2 top nuts are there to hold the actual sub-frame brace.
No modification to the 370z brace. ;) just a few flip backward and 180degree turn and it ended at 1 1/2'' from the frame. The setup use 1'' square tubing this is why the use of the nuts as spacer.
http://www.the370z.com/members/megan...re-exhaust.jpg

Once installed
http://www.the370z.com/members/megan...re-exhaust.jpg

Muffler clearance.
http://www.the370z.com/members/megan...dea-behind.jpg

You see what the goal was ?

http://www.the370z.com/members/megan...dea-behind.jpg


So no more picture but I plan to remove the exhaust from the car tomorrow for some more pictures and fixing a small issue that happened while welding the mid-pipe.


The exhaust was 95% completed on Thursday and I had to go for a drive !!!
I was more than happy about the noise of it !
It does not have an high pitched noise like a normal Y-Pipe setup but a very shaky base sound that can make you shake !!!! :yum:

While not a fan of the single exhaust look, that sounds really good. Nice Job :tup:

I want to see a picture of the single from further away! I keep seeing this!
http://www.caradvice.com.au/wp-conte...etta-MXT-3.jpg

Don't worry, it wont look anything like the picture you posted ! which is ugly !!!

Pics!! :excited:

Very nice work, look forward to seeing the finished product!!! :tup:

Great job. I love DIY :tup:

Good work
 

Sounds great

Have u figured out how your gonna seal around the exhaust @ the diffuser ?

Look at how.close the tip is to the stock diffuser, i wonder if the heat would melt that?? Maybe going with a carbon fiber one to take the heat.... U could even drill out the hole if u get the one without the fog light??

Yup I have an idea about how the next project will be. This will take some time thought.

This is just temporally. I'm not done with the exhaust. After Lunch I'm going back on it for some fixing.

the bottom part of the bumper wont be a problem soon anyway
It did melted a little bit around the tip.

Those are pictures that I miss to post !



This picture was taken when I was working on the Mid-pipe . It wasn't that easy going in & out & of the house & under the car after everything minor change in cutting/sanding.

http://www.the370z.com/members/megan...909-183147.jpg


Some bungs welded ! :)

http://www.the370z.com/members/megan...908-135411.jpg


This is earlier today when I welded the rod support on the mid-pipe

http://www.the370z.com/members/megan...914-180249.jpg


The look without the rear bumper cover. Can you visualize a future true diffuser ? ;)
http://www.the370z.com/members/megan...911-191328.jpg


The exhaust setup shown on this picture has been weighted at 39.6 Lbs.
This setup is currently 33 Lbs. lighter than my 2010 custom exhaust but it was made to be within a specific track noise decibel.
http://www.the370z.com/members/megan...7-39-6-lbs.jpg

Tomorrow morning, I will remove the Momentum and weight them to get the final result of how much lighter this setup will be over my pass one.
Then a wrapping session will be done on them. I forgot to buy another roll of 100ft the last time I made an order, I only have a 100ft 2''roll on hand.... ;/

this looks really sick

please post a video when ever you get the chance, i want to hear this bad boy ;)

NVM found video posted above XD

Wow that a true custom Megan!!!
Hats off:tiphat:
im looking forward to the finished product:tup:

This is what I had in mind to do, very nice job!

Wow freaking nice work! Are you going to cover the dual exit cuts on the OEM bumper?

I just think it'll look weird with a single exit in the middle and two cut outs.

Something will be done on the bumper itself in the next couple months.
I havent fixed my mind on what exactly but the lower part of the bumper will be cut for sure.

Some peoples request a Fly-by video !
Here it is as requested.

Yeah its dark, but who care ? the noise is still noise ! :)
Video took from a GoPro HD

That is incredible work. I've seen you do a lot of innovative stuff with this car over the years so I'm not surprised.

Many cars with a single exit in the middle of the bumper, although functional no doubt, look like they have a butt hole. I know you won't make that mistake!

Keep getting a Raddling / Rasping sound, I'm being told that its from the Berk test pipes do you know anyone else with the same problem real don't like it. Would changing them out for long tube headers solve my problem???

Sub'd

It wont. Mine doesn't and my EGT's are a bit hotter being FI.

Great job OP! Ive been looking to do a 3.5"-4" single so this may be the extra push I need.lol

I melted the **** out of one side of mine with a custom single that was too close, so don't be too sure lol

Oh and good work Megan, looks fantastic man.

yeah I melted a little bit around the tip but it was mostly because the muffler shifted a little bit on the side.
Nothing to worry since I only had like a few milimeter of clearance all around the muffler tip.

right now im debating on which project takes priority.

-Rear bumper/diffuser
or
-Custom Intake manifold w/ modular intake runner. + boxed SRI

It would look even more baller if the exhaust tip was shaped just like the oem opening on the bumper instead of the circular peg in the square hole look. Still, looks and sounds great, would love to see more pics

yeah I thought about a square-ish exit.
but when I think square single tip, I think about the Veyron.

http://wakpaper.com/large/Bugatti_wallpapers_102.jpg

I had the same issue when I put test pipes on, Hated it!! I guess its pretty common with our engines. I removed the test pipes and put Berk High Flow Cats on, they sound MUCH better! Took care of almost all the rasp, hopefully they last on my supercharged engine!