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clubstylus - View topic - Modifying exhaust from under car to side exit
It is currently Sat Nov 17, 2018 8:01 pm




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 Modifying exhaust from under car to side exit 
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Joined: Sat Apr 07, 2007 10:24 pm
Posts: 333
Location: Chester UK
Post Modifying exhaust from under car to side exit
Going to start a new thread (for those that are interested) about converting my 'under-slung asthmatic pea shooter style' smoke-exit into a proper sized, side exit jobbie....
Bear with me cos the light at the end of the tunnel was temporarily turned off - it appears to be re-lighting now though :lol:

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SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams, 236@fly. (aka NORMA)


Thu Feb 07, 2008 10:50 pm
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Joined: Wed Oct 17, 2007 9:29 am
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Location: Essex
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i'm listening :lol: I am doing it the way around, i have a 3 inch side exit but need to add a rear silencer as rotary engines are too loud.

I'm interested in the route from the side to the back of the car.

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Help! just starting out

Edit: Getting the hang of it............. Slowly


Thu Feb 07, 2008 11:46 pm
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Location: Chester UK
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Step 1:
Get Wunoff (in this case) to make a silencer to my spec (with a little help and advice from Rob :wink: )








Pay them about £250........

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SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams, 236@fly. (aka NORMA)


Fri Feb 08, 2008 3:50 pm
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Location: Chester UK
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Step 2:
3 weeks later, recieve said item....... :D


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SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams, 236@fly. (aka NORMA)


Fri Feb 08, 2008 3:51 pm
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Location: Chester UK
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Step 3:
Ok, this is where you need a stiff drink first....
Cut a bloody great big hole in the side of your car :cry:


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SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams, 236@fly. (aka NORMA)


Fri Feb 08, 2008 3:54 pm
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Location: Chester UK
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Oh, and after spending £30 on various saw blades, the winner (by a mile) is:
http://www.screwfix.com/prods/10553/Bla ... lade-300mm
absolutely brilliant, straight lines, doesn't catch and doesn't wear out either - and at under £4-00!!!

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SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams, 236@fly. (aka NORMA)


Fri Feb 08, 2008 3:57 pm
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Location: Chester UK
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Step 4:
Offer the box up.....




spend next 3 hours fettling the dam hole (!) to make it fit properly.... :?

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SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams, 236@fly. (aka NORMA)


Fri Feb 08, 2008 3:59 pm
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Location: Chester UK
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Step 5:
Go on Ebay and purchase some Kart exhaust bobbins, M8 female one end and male the other.
Then bash a couple of bits of stainless until they look almost presentable and get someone gifted (who can weld the stuff) to attach them for you.....
If you can do it yourself - then you're a smart arse :lol:





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SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams, 236@fly. (aka NORMA)


Fri Feb 08, 2008 4:04 pm
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Location: Chester UK
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Step 4.5:
oops! forgot to add, cut out excess amounts of probably structural fibreglass so that the exhaust runs no where near any.
Then spend a day adding fillets and bits of ally in a vain attempt to get some strength back around the front of the rear arch and also the rear of the front arch...


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SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams, 236@fly. (aka NORMA)


Fri Feb 08, 2008 4:07 pm
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Location: Chester UK
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Step 6:
Attach bobbins to exhaust and (in my case) through the sill to give the box plenty of support.
I then used a sill plate to help spread the load of the 2 countersunk stainless hex bolts I used to bolt through into the bobbin.....








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SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams, 236@fly. (aka NORMA)


Fri Feb 08, 2008 4:12 pm
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Location: Chester UK
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Step 7:
Start adding copious quantities of Rally design heat reflective fabric, get glue stuck to fingers and clothes and tools but not to fabric :x



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SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams, 236@fly. (aka NORMA)


Fri Feb 08, 2008 4:14 pm
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Well, thats as far as I've got (in 3 months !) ... will up date more as and when it happens.
Got a guy lined up to weld the manifold for me and just waiting for the steel tubing to arrive...
More random pics for you......








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SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams, 236@fly. (aka NORMA)


Fri Feb 08, 2008 4:18 pm
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Joined: Fri Mar 10, 2006 8:49 pm
Posts: 3750
Location: ASTON CLINTON BUCKS
Post Bobbins ?
Wrong way up I'm sorry to say though :cry: They will tear off after not too long due to weight and engine torque :wink: What's required is just ONE bracket bolted to the exit end of the silencer via the bolts holding the rear end and tailpipe on. Half moon shape 25mm wide then welded to that a 25mm leg sticking out parallel with the ground with hole drilled into it. That then sits on top of a bobbin which itself sits onto a bracket parallel with the ground and bolted through the passenger seatpan :roll: Bobbins are designed to take weight NOT hold it :wink:
Having two brackets will be a fight with the engine flex and ultimately the engine will win :cry:

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I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Fri Feb 08, 2008 7:11 pm
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Location: Chester UK
Post Re: Bobbins ?

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SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams, 236@fly. (aka NORMA)


Fri Feb 08, 2008 7:23 pm
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Location: ASTON CLINTON BUCKS
Post stress
The tighter you fix the silencer the greater the stress on the manifold . Also bolt size is irrelevant -- it's the bobbins that hold the weight and they normally fail at the metal/rubber join when hung as opposed to compressed :roll:

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I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Fri Feb 08, 2008 10:02 pm
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