Like pretty much everything else in this build, the dump pipe and exhaust had to be a custom job. I have bought all the parts for the entire exhaust system but will have to wait until I get both subframes and engine mounted in the shell before I can put it all together. Until then, I have fabricated the dump pipe. As I learnt a while ago, aftermarket dump pipes for the 4E-FTE engine foul against the subframe front brace bar so I had to custom make one.
After much reading of feedback on various forum, I chose 2.25" (57mm) exhaust for the car as a good balance between flow and noise levels. I have this size approved by the Department of Transport in my modifcation approval too.
I first made a cardboard template of the first bend that will come off the turbo outlet flange (I got the flange laser cut after providing them with the CAD design). This gave me the location and angle of the cut to make while clearing the the bell housing and front brace bar. Boy was it close too ... see below
To help keep the pipe in place and not having to tack the pipe directly onto the flange, I tacked on a flat piece of steel in the flange opening. I had to be quite careful here because if the angle of the pipe compared to the flange was even a bit off, it would foul against the front brace bar. It took 3 attempts to get it exactly right.
Its obvious above that the single pipe wouldn't cover the whole turbo outlet so I started cutting and shaping some pieces from another pipe bend to cover either side of the flange. I wanted the angle of the bellmouth section to be a smooth progression into single pipe, so the pieces were made longer. The process of getting these small pieces shaped, rounded and moulded to the flange opening took over 4 hours!
The result :
From there, it was a simple case of measuring and tacking together the other pieces of pipe down and under the sump, and making a hole for the Oxygen sensor. I will also have to make a hole for the EGT probe I will be fitting and the entire pipe will be TIG welded and eventually ceramic coated. A 6" braided stainless steel flex pipe will be mounted directly after the dump pipe flange.
The clearance between the dump pipe and front brace bar was only 5-6mm. I wasn't happy with that small clearance so I welded a small piece of exhaust tube into the front brace to create a small scallop and give a total of 10mm clearance in case the engine moves a lot eg. under heavy braking.
Update :
I had the dump pipe TIG welded and then I recently welded on a bung for an Exhaust Gas Temperature (EGT) probe.
After much reading of feedback on various forum, I chose 2.25" (57mm) exhaust for the car as a good balance between flow and noise levels. I have this size approved by the Department of Transport in my modifcation approval too.
I first made a cardboard template of the first bend that will come off the turbo outlet flange (I got the flange laser cut after providing them with the CAD design). This gave me the location and angle of the cut to make while clearing the the bell housing and front brace bar. Boy was it close too ... see below
To help keep the pipe in place and not having to tack the pipe directly onto the flange, I tacked on a flat piece of steel in the flange opening. I had to be quite careful here because if the angle of the pipe compared to the flange was even a bit off, it would foul against the front brace bar. It took 3 attempts to get it exactly right.
Its obvious above that the single pipe wouldn't cover the whole turbo outlet so I started cutting and shaping some pieces from another pipe bend to cover either side of the flange. I wanted the angle of the bellmouth section to be a smooth progression into single pipe, so the pieces were made longer. The process of getting these small pieces shaped, rounded and moulded to the flange opening took over 4 hours!
The result :
From there, it was a simple case of measuring and tacking together the other pieces of pipe down and under the sump, and making a hole for the Oxygen sensor. I will also have to make a hole for the EGT probe I will be fitting and the entire pipe will be TIG welded and eventually ceramic coated. A 6" braided stainless steel flex pipe will be mounted directly after the dump pipe flange.
The clearance between the dump pipe and front brace bar was only 5-6mm. I wasn't happy with that small clearance so I welded a small piece of exhaust tube into the front brace to create a small scallop and give a total of 10mm clearance in case the engine moves a lot eg. under heavy braking.
Update :
I had the dump pipe TIG welded and then I recently welded on a bung for an Exhaust Gas Temperature (EGT) probe.
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