My custom built 76mm exhaust..long read

2817 Views 22 Replies 4 Participants Last post by moshaholic2, Mar 9, 2014

Drifter

Discussion Starter · Mar 8, 2014

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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Drifter

Discussion Starter · #2 · Mar 8, 2014

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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Drifter

Discussion Starter · #3 · Mar 8, 2014

Reducing the 85mm turbo flange exit to 76mm

Welded on inside

Double welded on outside to prohibit cracking and breakage

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Drifter

Discussion Starter · #4 · Mar 8, 2014

First bend welded into the system, completely seamless

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Drifter

Discussion Starter · #5 · Mar 8, 2014

Next up, 76 mm concertina flexi, triple welded through all three layers.

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Drifter

Discussion Starter · #6 · Mar 8, 2014

First lambda bung gets strategically placed

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

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Drifter

Discussion Starter · #7 · Mar 8, 2014

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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Drifter

Discussion Starter · #8 · Mar 8, 2014

Stainless Steel high flow resonator gets prepped.

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

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Drifter

Discussion Starter · #9 · Mar 8, 2014

A few bends, some welds, a downstream lambda and a resonator.

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

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Drifter

Discussion Starter · #10 · Mar 8, 2014

Now a flange to split the system.

We use V-band flanges as it also creates a seamless link.

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Drifter

Discussion Starter · #11 · Mar 8, 2014

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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Drifter

Discussion Starter · #12 · Mar 8, 2014

You then cut your hand, draw a Pentagram on the floor, light some candles...Witchcraft happens, and the whole system becomes shiny.

https://www.youtube.com/watch?v=8wrCWFe ... e=youtu.be

Now, lets wrap this baby for final fitment.

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Drifter

Discussion Starter · #13 · Mar 8, 2014

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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Drifter

Discussion Starter · #14 · Mar 8, 2014

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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Drifter

Discussion Starter · #15 · Mar 8, 2014

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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Drifter

Discussion Starter · #16 · Mar 8, 2014

Custom double welded Oval silencer

Still has protective wrapping on it.

Custom made 76mm tips with slash cut

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Drifter

Discussion Starter · #17 · Mar 8, 2014

Rear section completed

It is done !!!!

Video

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Drifter

Discussion Starter · #18 · Mar 8, 2014

And that is how we do it in South Africa when the exchange rate sucks.

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Drifter

Discussion Starter · #20 · Mar 8, 2014

I know, every weekend I crawl under the car just to perve. Thanks buddy.

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Drifter

Discussion Starter · #22 · Mar 8, 2014

Yes, stock tune. I gained 10wkw and 50NM at 2500RPM. Took a while for the exhaust to bed in, but as you know it will always need a little carbon build up before its at its best. In hindisight , i should have put on more mileage before I did the after dyno. Big plus is that fuel consumption is also better, guess thats power to weight ratio working right there.

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