DIY low budget stainless side exit exhaust for 92 L300
Posted: Sun Aug 07, 2016 2:51 pm
I've been watching my Deli's exhaust slowly disintegrate on my '92 Starwagon and the pain of patching has exceeded the pain of spending real money on a new exhaust setup so I started collecting parts for the new setup. I couldn't see paying $1,000 dollars to a shop for what amounts to 3 welds and less than $200 dollars in metal so I started formulating a plan and collecting parts. Turns out one of the hardest parts was locating a local welding/fabrication outfit (Seattle area) that was willing to work on a 1 hour project and that would TIG with stainless filler rod.
I measured the angle between the turbocharger outlet (book calls it an exhaust fitting) and what I thought was a good angle for the side pipe exit. It came out to 52 degrees on a protractor I stole from my sons school backpack. I took that measurement and went to Stan's Headers in Auburn, WA. (253) 854-5310. Stan's has the only mandrel bender I found in my area. They came up with 50 degrees. In hindsight, I could have ordered a 50 degree bend from Amazon for much cheaper. Maybe half of what I paid (109$) The guys at Stan's were awesome and I probably would have had them do it all if they weren't booked out over a month.
Next I did the same for the tailpipe, guessing that a 60 degree bend would work out ok for the exit. This piece came from Amazon (Vibrant (13070) 60° T304 Stainless Steel Mandrel Bend Tube, 37.97$)
I ordered the muffler from Amazon (Magnaflow 10416 Satin Stainless Steel 2.5" Round Muffler, 64.10$)
The flange came from Ebay. (2 Bolt Universal Flange with 2.5" ID hole CNC 3/8" Thick Exhaust Custom Weld On, 18.95$)
More on the flange later. I ended up going with slotted holes because I didn't get a good feel about the measurements I found on here.
The only other thing I needed was a gasket and a piece of stainless rod to use as a hangar. And somewhere to weld it all up.
So far I'm into it for 246$
Tail pipe - 37.97$, Vibrant (13070) 60° T304 Stainless Steel Mandrel Bend Tube, Amazon
Down pipe - 109.00$, Stans Headers, Auburn Wa. Local
Flange - 18.95$, 2 Bolt Universal Flange with 2.5" ID hole CNC 3/8" Thick Exhaust Custom Weld On, Ebay
Muffler - 64.10$, Magnaflow 10416 Satin Stainless Steel 2.5" Round Muffler, Amazon
Gasket - 1.40$, Local Auto store Issaquah Wa, Oreilly's I think.
Between procrastination and real (non Deli) life it took me about 4 months to get my act together.
Pics next.
Pile of parts waiting, and growing
I measured the angle between the turbocharger outlet (book calls it an exhaust fitting) and what I thought was a good angle for the side pipe exit. It came out to 52 degrees on a protractor I stole from my sons school backpack. I took that measurement and went to Stan's Headers in Auburn, WA. (253) 854-5310. Stan's has the only mandrel bender I found in my area. They came up with 50 degrees. In hindsight, I could have ordered a 50 degree bend from Amazon for much cheaper. Maybe half of what I paid (109$) The guys at Stan's were awesome and I probably would have had them do it all if they weren't booked out over a month.
Next I did the same for the tailpipe, guessing that a 60 degree bend would work out ok for the exit. This piece came from Amazon (Vibrant (13070) 60° T304 Stainless Steel Mandrel Bend Tube, 37.97$)
I ordered the muffler from Amazon (Magnaflow 10416 Satin Stainless Steel 2.5" Round Muffler, 64.10$)
The flange came from Ebay. (2 Bolt Universal Flange with 2.5" ID hole CNC 3/8" Thick Exhaust Custom Weld On, 18.95$)
More on the flange later. I ended up going with slotted holes because I didn't get a good feel about the measurements I found on here.
The only other thing I needed was a gasket and a piece of stainless rod to use as a hangar. And somewhere to weld it all up.
So far I'm into it for 246$
Tail pipe - 37.97$, Vibrant (13070) 60° T304 Stainless Steel Mandrel Bend Tube, Amazon
Down pipe - 109.00$, Stans Headers, Auburn Wa. Local
Flange - 18.95$, 2 Bolt Universal Flange with 2.5" ID hole CNC 3/8" Thick Exhaust Custom Weld On, Ebay
Muffler - 64.10$, Magnaflow 10416 Satin Stainless Steel 2.5" Round Muffler, Amazon
Gasket - 1.40$, Local Auto store Issaquah Wa, Oreilly's I think.
Between procrastination and real (non Deli) life it took me about 4 months to get my act together.
Pics next.
Pile of parts waiting, and growing