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Old 03-16-2005, 04:40 PM   #1 (permalink)
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Default FooK How-To: Making a downpipe

Well, I started on my downpipe, so I figure I will throw out some instructional along with a little picture action.

Tools:

Welder
Chop Saw
Sharpie

Materials:

One 180* mandrel bend
flex section
Turbine Outlet flange
flange to match catylitic
1.75" material for dumptube

Costs:

These costs reflect the prices I paid from where I got my parts, you CAN get some of these things cheaper, or for more.

14b flange - $20 (bmcrace.com)
180 degree U-bend - $13 (tunertoys.com by email only)
o2 bung - $7 (zeitronix.com)
Flex Section - $15 (friend)
2 Bolt Flange to match Catylitic - ? (haven't purchased yet)

What to do:

Basically I started by chopping the 180* bend in half at the center.

Then I started working my way from the turbo on back cutting pieces to fit as I go, tacking it together as I get each piece. On mine I built it without the flex to get the length, then i will add it in at work tomorrow because i needed to modify it a bit. With it all tacked like in the pics below, I will weld it all up, add the flex section, add an end flange, and I will also be welding in two o2 bungs, one for my stock o2, and one for my wideband. I will buy a plug for the wideband bung when its not in use.

Here are the pics all tacked up.





UPDATES!

Now that I had it all mocked up I was able to take it to work to get in some quality time with completing it.

Here are some more pics, got the flex in and welded and will be getting bungs and a rear flange soon

Welding action love pic, looks decent for a mig


couple shots of the whole thing



One section that didn't turn out to be much in the eye candy department. I'll do some grinding tomorrow on lunch or something and make it look good.


Tomorrow when I get home from work I should have o2 bungs and a wideband in the mail, so I will have the bungs to weld in, and then I will get a 2 bolt flange to put on the end, then its time to sort out the dumptube, its a tight fit around the slave cylinder so I think I am going to buy some 90 bends from mcmaster to get it bent up tight and make it all look nicey nice.
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Old 03-16-2005, 04:45 PM   #2 (permalink)
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Very Very Nice!!!!!!
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Old 03-16-2005, 04:50 PM   #3 (permalink)
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yup nice
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Old 03-16-2005, 04:55 PM   #4 (permalink)
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looks good!! did you do the welding yourself?
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Old 03-16-2005, 05:29 PM   #5 (permalink)
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wow nice job man. that flange weld looks great!

post up what welder ur using etc etc
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Old 03-16-2005, 06:08 PM   #6 (permalink)
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Originally Posted by ryan89crx
looks good!! did you do the welding yourself?

negative, why use my shitty amateur welding skill when i have 3 people that do it all day long at my disposal, ya know?

welder used was an ESAB Migmaster 250 mig welder.

whats up with d-series? im not getting any email notifications

Last edited by FooK; 03-16-2005 at 06:14 PM.
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Old 03-16-2005, 06:10 PM   #7 (permalink)
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sexxxy down pipe .... to the welder
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Old 03-16-2005, 06:51 PM   #8 (permalink)
 
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awesome man!!!
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Old 03-16-2005, 06:55 PM   #9 (permalink)
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aww damn.. i thought maybe it was a welder I COULD ACTUALLY AFFORD lol... damn i wish i had more money lol
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Old 03-16-2005, 07:30 PM   #10 (permalink)
 
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awesome job man! u saved like 200-300 bucks
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Old 03-16-2005, 07:57 PM   #11 (permalink)
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Quote:
Originally Posted by FooK
whats up with d-series? im not getting any email notifications
i never get email notifications, i kind of like it that way...
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Old 03-16-2005, 08:31 PM   #12 (permalink)
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if i never get notifications i never know when to check posts, and then i forget the site is there at all.
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Old 04-07-2005, 07:57 PM   #13 (permalink)
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***UPDATE***

project downpipe complete

finished the downpipe. paint i used said it needs to sit in the warm to cure. not sure what disease it has, but it needs a cure.
fyi- paint used is made by VHT (very high temperature) and is rated at 1300-2000*F...flat black goodness. Pics suck but I did what I could with what I got.

I'm pretty proud of this DP, it turned out really nice, even with me finishing up the welding, which I still suck at.


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Old 04-07-2005, 09:31 PM   #14 (permalink)
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damn looks real good wanna build me a turbo kit?
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waiting to hear from this dude right now bout that tranny. lol...hopefully he will meet me somewhere.
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Old 04-07-2005, 09:34 PM   #15 (permalink)
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the purpose of a DIY is (do it yourself)
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Old 04-07-2005, 09:44 PM   #16 (permalink)
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Quote:
Originally Posted by FooK
the purpose of a DIY is (do it yourself)
ive never touched a welder in my life and i dont have access to one Im just gonna have to pay someone else to do it.
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waiting to hear from this dude right now bout that tranny. lol...hopefully he will meet me somewhere.
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Old 04-07-2005, 10:17 PM   #17 (permalink)
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Quote:
Originally Posted by 98CiviCn00b
ive never touched a welder in my life and i dont have access to one Im just gonna have to pay someone else to do it.
someone told me that Sears will rent out welders... if they don't, i know that SOMEONE does. You just need a space to do it... which i don't have living in an apartment complex
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Old 04-07-2005, 10:20 PM   #18 (permalink)
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Quote:
Originally Posted by 98CiviCn00b
ive never touched a welder in my life and i dont have access to one Im just gonna have to pay someone else to do it.
naw get some scrap metal practice for a bit then do it. I'm a rook at welding, but I've done a few things that came out fine.
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Old 04-08-2005, 12:11 AM   #19 (permalink)
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damn dude, that doesn't look bad at all..........nice work dude........I'm impressed. rep for you for going semi-DIY
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Old 04-08-2005, 01:20 AM   #20 (permalink)
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professional looking to me, good work !
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