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Discussion Starter · #1 ·
So, dropped the Driftmobile V2 off at KontrolFreakz for custom exhaust build. I will try and keep this thread going as a work in progress thread, so you guys can see it's not just a matter of slapping on a pipe.

Really LOTS of work need to be done:


Before all started




On the lift




Prepping started

Need to remove engine cover, lights, induction and water bottle.




Wiper removal

Need to removethe wipers and slide out the wiper blades



Remove induction:

Need to remove induction to get access to the top bolt on the DP.


Now, need to get past that heat shield so we can access the DP.



more to come .....
 

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Discussion Starter · #2 ·
Stock Down pipe and CAT

What a fugly thing!!



Stock CAT Back



Bye Bye Stock Exhaust



High Spec heat wrap


After a lengthy duscussion with PhillipI took his advice and asked him to heatwrap the DP, This high spec heat wrap.



Turbo Flange cut and ready

This is for the new 76mm DP. Look at the workmanship, this guy doesn't rest.





 

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Discussion Starter · #3 ·
Reducing the 85mm turbo flange exit to 76mm






Welded on inside





Double welded on outside to prohibit cracking and breakage

 

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Discussion Starter · #6 ·
First lambda bung gets strategically placed

A 18mm hole gets drilled and bung welded into place.



 

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Discussion Starter · #7 ·
The experience comes in when you have to use pre-made Mandrel bends, where to cut them, how to cut them and at what angle to cut them, to make the system go
in the direction you want, whilst using as little as possible bends to optimize flow to increase performance.



When you grind through the steel, it ends up with a very ugly edge. Every single cut gets belt sanded and de-burred to get a smooth weld with nothing protruding
on the inside of the exhaust system.



 

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Discussion Starter · #8 ·
Stainless Steel high flow resonator gets prepped.

Double welded end pipes to make it easier to weld onto the system.







 

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Discussion Starter · #9 ·
A few bends, some welds, a downstream lambda and a resonator.

We are almost done with the down pipe. Phew!!!







 

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Discussion Starter · #11 ·
An extension and two exhaust hangers. and you end up with a complete down pipe.







No, thats not me. It's Nishen from KontrolFreakz.
 

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Discussion Starter · #13 ·
Mini CAT fooler





Every single nut, bolt or sensor gets a dab of copper anti seize compound before they go back in.

 

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Discussion Starter · #14 ·
Final fitment in place

Now to put all the engine components back together, start up and check for leaks. Once it has a thumbs up, rear section can be started.





 

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Discussion Starter · #15 ·
Cat back almost there

How the heck am I going to keep it that shiny? Look at the last pic, like a snake waiting to pounce on the 1st A4 1.8T it finds
(sorry RF, just had to)

Look at the welds, seamless, just perfect.







 

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Discussion Starter · #16 ·
Custom double welded Oval silencer

Still has protective wrapping on it.





Custom made 76mm tips with slash cut



 

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That is such a good looking exhaust, it seems a shame to wrap it like that. Or hide it under the car for that matter :D
 
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