My Homemade 3" Exhaust

musclemerc

musclemerc

Senior Member
I fabricated a 3" mandrel bent exhaust system for my Marauder.

I did the build on my back in the shop. If it's not the hardest thing I've ever fabricated it's definitely up there in the top 5.

The exhaust is all T409 SS (except for the rear mufflers), V band connectors, all mandrel bends, 9" race mufflers off the collectors and 27" super turbo mufflers out back. I kept the resonators in the stock tips, and reused the factory dampeners on the mufflers.

I built the center section first, then set the mufflers where I wanted them.
The cross section for the H is 2.5"

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To get over the axle I had to get the weight of the vehicle on the ground so I picked up some concrete 16x16x4 pads.


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The bends over the axle have V bands on both sides to make removing them an easy task.

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I still have to set my tips but the hard work is now over with.

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I decided against using TIG and went with the speed of my MIG. All the welding wire is 308L SS wire.


She sounds pretty mean. The tone is deep and throaty.

Lucky for me I didn't have to chase down a single leak.

All in all I may have spent $800.00 in parts and countless hours fabricating this kit.
 
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Glad that all worked out. I have the old Stainless Works 3" kit, and nothing really lined up. In short, it was a headache. All good now though.
 
Left side tail is crooked. [emoji6] LOL

Looks damn good Travis! I’m surprised you didn’t enjoy it? I love making my own pipe stuff if time allows. I just wish I had better shop equipment.. I have three nice portabands, a crappy table bandsaw (soon to be in the garbage), but not a nice if even cheap horizontal one which would be the ticket.

I would highly recommend that you add V bands right off the collector if your not already. After a few heat cycles, condensation, and age, the X will be a bear to get off and back on without them.


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Bad_S55 said:
Glad that all worked out. I have the old Stainless Works 3" kit, and nothing really lined up. In short, it was a headache. All good now though.
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Mine took serious massaging with 2 x 4’s to bend it right without dinging it up... Mostly the X and right side tail pipe. It took two more adjustments later to get it close to right! The muffler hangers were also bent oddly and too short. One even broke loose and fell off a couple of years ago. And I’ve done hundreds of systems as my job in my younger years. I could never imagine how anyone that hasn’t done many could ever get it to work..


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If I need to drop the LT's in the future I'll put them on. I ordered a spare pair just for that.

For now they got old school U clamps holding them in place
 
This is quality work right there and it,s very well done travis :)

are the mufflers stainless steel ? all the turbo styles mufflers I have been looking for are all aluminized.
x2 on using mig for the whole job , I will do the same when I get there
 
2004_p71 said:
This is quality work right there and it,s very well done travis :)

are the mufflers stainless steel ? all the turbo styles mufflers I have been looking for are all aluminized.
x2 on using mig for the whole job , I will do the same when I get there
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I'm glad you asked this question Pier. I amended the thread, thanks for reminding me.

The mufflers are all Dynomax... The front 9" mini race bullets are SS.
The rear 27" super turbo mufflers are aluminized

Didn't intend to mislead anyone. :violin:


I looked and looked but when they get this big aluminized is the only option.


I was dead set on turbo mufflers, they came stock on the MM.
 
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I thought the front ones were cats ;) at that size do they do any difference ?

I have been looking myself for all stainless steel Turbo mufflers for over a year. I had the full SW kit with their ''turbo'' muffler and as much as it sounded great at the track for a daily driver I really hated it. I'm looking for something MUCH more civilized for a daily driver and looks like the dynomax is the only option so far . Is there any drone at all ? .
 
Thats a great looking system you fabricated , I remember helping the fabricator do mines many late nights till 1 or 2am he said he wouldn't do another one as it was far to time consuming with all of the Tig welding and building the different angles , but definetly worth it I bet your loving that deep rumble!
 
MOTOWN said:
Thats a great looking system you fabricated , I remember helping the fabricator do mines many late nights till 1 or 2am he said he wouldn't do another one as it was far to time consuming with all of the Tig welding and building the different angles , but definetly worth it I bet your loving that deep rumble!
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Thanks Roger. I used your thread as a template to help build mine.

What did he do on the DS to get around the ride height sensor and the watts?

Did you have the work done on your car with the mini tub?

The DS was a nightmare to fit 3" dia. pipe
 
2004_p71 said:
I thought the front ones were cats ;) at that size do they do any difference ?

They're suppose to cut 4db of noise

I have been looking myself for all stainless steel Turbo mufflers for over a year. I had the full SW kit with their ''turbo'' muffler and as much as it sounded great at the track for a daily driver I really hated it. I'm looking for something MUCH more civilized for a daily driver and looks like the dynomax is the only option so far . Is there any drone at all ? .
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I plan on taking her out later today

1stMerc said:
Nicely done. You'll be glad you went with the stock resonated tips.
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I agree, the first crank without them was LOUD
 
Ive always went with the mig much faster

I would think unless your making big power dual 2.5s would be better suited and easier to work with

Ive always been a fan of the super turbo muffs on race cars. On a daily though I much prefer a quiet stock exhaust

looks good tho
 
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