Modifying exhaust from under car to side exit

Here you can discuss/show your (re)build progress and (would be) mods.
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norma
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Re: Modifying exhaust from under car to side exit

Post by norma »

what's the bet it falls off tomorrow now! :shock:
SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams, 236@fly. (aka NORMA)
stylussprinter
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Re: Modifying exhaust from under car to side exit

Post by stylussprinter »

It is certainly amazing that it's stood the test of time. The SSC zetec engine mount rubbers are bonded onto the metal plates exactly the same way and they are used in compression ------------ one of mine still gave way after 3 years on the drivers side which tends to lift under power :roll:

It's a bit like being told not to smoke (a good thing ) then watching a man of 97 years smoking a pipe while digging his garden :lol:
I just love the Stylus but she keeps swallowing £££ !
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.
spegru
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Re: Modifying exhaust from under car to side exit

Post by spegru »

Right I think I'm going to do this (worried about current underslung being too close to fuel tank).
So it looks like Wunoff for the exhasut can, but does someone have a design for a manifold? (I never made one of those before)
thanks
stylussprinter
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Re: Modifying exhaust from under car to side exit

Post by stylussprinter »

spegru wrote:Right I think I'm going to do this (worried about current underslung being too close to fuel tank).
So it looks like Wunoff for the exhasut can, but does someone have a design for a manifold? (I never made one of those before)
thanks
Like I said , just get the primaries equal length ---- I could send you a photo :?:
I just love the Stylus but she keeps swallowing £££ !
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.
spegru
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Re: Modifying exhaust from under car to side exit

Post by spegru »

Yes I got the point about equal lengths, but I had been hoping for an actual design since I've never made one.
Photos would be helpful of course. Thanks
What kit of bends etc did you use?
stylussprinter
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Re: Modifying exhaust from under car to side exit

Post by stylussprinter »

spegru wrote:Yes I got the point about equal lengths, but I had been hoping for an actual design since I've never made one.
Photos would be helpful of course. Thanks
What kit of bends etc did you use?
I had it made at EXHAUSTS BY DESIGN near Buckingham , on the car . I supplied the silencer plus it's mount and had already cut out the f/glass sill .
Attachments
my new design 'A' frame opens very wide and stays up on it's own.jpg
I just love the Stylus but she keeps swallowing £££ !
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.
spegru
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Re: Modifying exhaust from under car to side exit

Post by spegru »

Thanks. Do you have a pic of the 4:1 collector down in the sill?
stylussprinter
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Re: Modifying exhaust from under car to side exit

Post by stylussprinter »

These are a bit dark but best I could do :roll:
Attachments
Exhaust manifold 003.jpg
Exhaust manifold 002.jpg
As you can see -- after the 4 into 1 collector the 2.75 inch pipe ' dog-legs ' down so's the silencer can be level and away from the chassis .
As you can see -- after the 4 into 1 collector the 2.75 inch pipe ' dog-legs ' down so's the silencer can be level and away from the chassis .
I just love the Stylus but she keeps swallowing £££ !
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.
spegru
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Re: Modifying exhaust from under car to side exit

Post by spegru »

Norma, I see from your drawing that there is an offset tube/dog leg with dimensions X and Y. Do you have the figures for X and Y?

steve
spegru
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Re: Modifying exhaust from under car to side exit

Post by spegru »

Rob thanks for those new pics. A nice piece of work.
I see that you also have a dog leg. By the look of it, it brings the centre of the pipe up to a level in line with the top edge of the silencer and about 6in long. Correct?

I just had a chat with Wunoff and they advised against basalt (which is what I was going to go for from other comments here about noise level) because it apparently goes lumpy and starts rattling due to heat. Can anyone comment on that?

Thanks
stylussprinter
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Re: Modifying exhaust from under car to side exit

Post by stylussprinter »

spegru wrote:Rob thanks for those new pics. A nice piece of work.
I see that you also have a dog leg. By the look of it, it brings the centre of the pipe up to a level in line with the top edge of the silencer and about 6in long. Correct?

I just had a chat with Wunoff and they advised against basalt (which is what I was going to go for from other comments here about noise level) because it apparently goes lumpy and starts rattling due to heat. Can anyone comment on that?

Thanks
Yes I can comment = BOLLOCKS :?: Mines been in for over two years without ever repacking . It has to be a repackable silencer , I wouldn't even think about a non repackable no matter what packing you use. Nothing else will lower db's by such a huge chunk , I've been competing for 10 years and have tried everything , sometimes having to repack for every event afresh using rockwool , then e glass --- no better . Just get them to make the silencer then pack it yourself :wink:

Dog leg ------------ norma took my measurements to create his drawing so it'll be as his ok It's more like 8 inches not 6 . I didn't draw it out , I don't do things that way. First I cut out the area of fibre glass that I needed to get my 6 inch diameter silencer in , which was 50mm or 2 inches cut below the door sill plus right back to the alloy sheet on the chassis. After that I simply rounded off a nice shape each end purely for easthetics plus clearance from f/glass . Mounted the silencer bracket at the rear then propped up the silencer with wood blocks to get it parallel to the door sill . Only then did I decide what dog-leg would be needed --- the manifold was the last thing to get designed.
I took the car to him , propped up the silencer for him to see the distance he'd need to pipe for the lengths I wanted. Collected the car the following week -- job done :wink:
I just love the Stylus but she keeps swallowing £££ !
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.
stylussprinter
Stylus owner
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Joined: Fri Mar 10, 2006 8:49 pm
Are you a Stylus owner?: yes
Location: ASTON CLINTON BUCKS

Re: Modifying exhaust from under car to side exit

Post by stylussprinter »

Just checked the dog-leg and it's 10 inches long including the split end 3 inches for joining up.That's distance from silencer to join --- not pipe length which being dog-legged is actually longer.
Also -- the top of the inner dog-leg is 20mm's higher than the top of the silencer as opposed to being level as you thought. This makes it possible for the silencer to hang out 20mm's from the body and almost level with the ground -- as well as clearing all f/glass.
I just love the Stylus but she keeps swallowing £££ !
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.
spegru
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Re: Modifying exhaust from under car to side exit

Post by spegru »

Thanks again for everything.
When you say 'split' I suppose you mean the split pipe for jointing the sections?
When you say 'almost level with ground' you don't really mean almost no ground clearance do you?
Finally when you say "top of the inner dog-leg" to you mean top of the pipe or the upper end measured at centre line?

Sorry to keep asking fine details......
stylussprinter
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Re: Modifying exhaust from under car to side exit

Post by stylussprinter »

spegru wrote:Thanks again for everything.
When you say 'split' I suppose you mean the split pipe for jointing the sections? YES :)
When you say 'almost level with ground' you don't really mean almost no ground clearance do you? SHOULD HAVE SAID PARALLEL :wink:
Finally when you say "top of the inner dog-leg" to you mean top of the pipe or the upper end measured at centre line? TOP OF THE DOG-LEG PIPE THAT'S IN THE ENGINE BAY SILL & THEREFORE HIGHEST POINT :wink:

Sorry to keep asking fine details......
I just love the Stylus but she keeps swallowing £££ !
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.
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norma
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Re: Modifying exhaust from under car to side exit

Post by norma »

only just seen this post - sorry :oops: tried to upload a pdf - it wont let me....will try something else...wont let me do that either...why??
oh well, pm me your email address if you still want it.....
spegru wrote:Norma, I see from your drawing that there is an offset tube/dog leg with dimensions X and Y. Do you have the figures for X and Y?

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