hi guys,

Well I need to rack your brains again as, wait for it.....I am going to MAKE a cat back exhaust for my 1.8t slxi, I know what your thinking, but how hard can it be its just some bits of pipe right?.

O.K......I will come clean, I am a sheet metal worker and the company I work for makes stainless exhausts for the hgv market, trains, jcb, lorries etc..

What I need is any advice about pipe sizes etc (2" or 2.5"?) the whole system will be made in t304 (the good stuff)

and hopefully sound deep but not loud, I am thinking about a single 5" round box for the middle, straight through perf wrapped in inch thick steel wool then glass packing, then for the back box twin 5" round boxes made the same way, but welded together and using a 1 into 2 configuration ( a 'Y' pipe) , the tail pipe(s) can be anything I like (open to suggestions) though if I want them to stick out the back of the car they will be quite long and to avoid droning I may have to exit into 2.5" pipe and add a shorter tailpipe(s) on the end, though if I am correct the rs tailpipe is quite long...?

Really what I am after is any help or advice off any one who has done something similar or has a custom system that sounds nice.

Cheers fram

Ask Dave (DaveU) to send some pics of his custom Powerflow cat back exhaust and dimensions (if possible).

I think Dave had a 2.25'' diameter made up with a very small rear box (he likes 'em loud:D ). Generally most aftermarket systems are 2.5''.

I have a Jetex cat back system and the tailpipes exit the rear box quite low and have to come upwards and straighten out to exit the bumper cut out. I can take some pics and post to you if you like.

Check out varios exhaust threads in Performance to view pics on tailpipe designs.

Cheers.

Adrian.

thanks mate,

yes any pics would be really helpfull, when I did the system for my old pug 306 it was a bit trial and error fitting wise, I am going to try and be a bit more precise this time, I think the standard sytem seperates into three bits, cat, middle, and rear, which is handy for jigging up, the real problem is the sound, as its a family car this time not just for me to use, I will have to be a bit conservative, i.e. nice and deep as opposed to full on nova......

If daveU reads this, mate it sounds like you could be a real help to me, any info pics appreciated.

Cheers Fram

Hi Fram,

I've got a load of pics at home - i'll put them up later tonight for ya

Fram,

mines is a family car to and I had same concerns as you're having. Jetex makes the car sound meaty but it is overly loud. Mind you the rear box is huge!

Will take some pics when I get home and will post then here tomorrow.

Cheers.

Adrian.

wow thats what I call quick..

thanks dave, really appreciate it, and yep adrian if I make the octy sound like a touring car SWMBO will hit the roof and the nipper will go prematurely deaf (wait till hes a teenager then he can do it him self, with his nova...yeah right!!)

cheers FRam

Fram - I will be watching with interest ....

Why not make it in the style of a BPM twister backbox

(see attached pics below)

One small problem though......it was the loudest exhaust i've ever heard.

Phil.

Pics should appear shortly

Good gawd! :eek:

No offence but that is one of the most revolting looking exhausts I have ever seen in my life! :eek: :eek: :eek:

can someone repost the pics - can't get to them - or is it too horrible for that - Clarey it was a joke, right?

Trouble with webspace, i think.

I'll attach one now.

And another.

And fitted.

I thought it was close to how fram had described, except it goes 1 into 3, rather than 1 into 2.

Hmmm - yes I think I understand now

Presumably it makes your car sound like the Divine Wind? :p

The idea behind its design is.....

The gases exit the exhaust with a vortex type motion, due to the twisting action of the corkscrew type inserts in the backbox. This is supposed to work like a dyson vacuum cleaner, and actually suck the gases out of the exhaust.

The reality was......it had a unique sound, just too loud.

P.S i no longer have the car or the exhaust.

hi guys,

Well erm....nice zorst clarey..I think...the basic idea I had was to actually make two bike exhausts (though I usually make them in 3.5" not 5") and weld them together to make a twin, the outlets would either be twin pipes or a 4.5" x 2.5" oval slash cut at 20 degrees, I quite like the oval idea but don't know how it would look sticking out UNDER the bumper...(mmm, note to self, see if rs rear bumper will fit slxi...) I will make the system first and then try several different tail pipe ideas until I am happy with one!!

Cheers Fram

Fram,

as promised some exhaust pics for you:

..and another:

...and another:

Thanks mate that solves one problem and creates another.....

I am in the process of jigging up the exhaust as we speak, when each section has been made I will post pics for all to see...whatch this space....erm...actually dont it might take a while...but I will let you know!!

Cheers Fram

Are you going to have a visible tailpipe(s) Fram? Your car and mine are similar in that they have the hidden downturned tailpipes behind the bumper. Mines made worse by the Skoda body kit that adds another 4 inches or so to the bottom of the bumper ... :(

hi Nick,

I am actually going to have a visible tailpipe, an oval slash cut i think though I may change my mind as I go along, the tailpipes are the last bit to be welded on to the system (stops them getting scratched and dinted) so when I dry fit the system I will make up a couple of different ones and see what looks best!!

Fram,

are you going to have the tail pipes coming from under the rear bumper or are you going to cut it?

Slash oval.........nice.

Cheers.

Adrian.