C5 Z06 180 degree header build thread

[coltboostin]

wow

[AudiOn19s]

I can't wait to hear this when complete. I had Matt make me an exhaust for my GT3 that sounds like no other. I get asked at every track day where I got my exhaust and how people can duplicate the sound!!! I have no doubts this will be even more intriguing than anything he has made to date.

[caseyctsv]

Simply amazing. I would have to assume there is a lot more on,say, a Camaro?

[Tinman]

A little progress. Both Collector merges tacked up.

 

http://i157.photobucket.com/albums/t55/tinman_015/IMG_1926.jpg

 

I'm surprised no one has asked how I'm going to weld the tubes together where they first meet at the merge. They are too close together to make a full weld around the outside and there is no way to get a torch through the 1 5/8" x 3 1/4" oval exit to weld on the inside... Pencil torch!

 

http://i157.photobucket.com/albums/t55/tinman_015/IMG_1918.jpg

 

http://i157.photobucket.com/albums/t55/tinman_015/IMG_1922.jpg

 

Made a sample megaphone from 16ga. carbon steel at work to make sure it would work. Plasma cut on our CNC plasma table from our Vulcan ductwork and fitting software and then step broke up in our press brake. 1 3/4" x 3 1/2" o.d. to 2 1/8" x 3 1/2" o.d. to match the oval tubing I plan to use to start the X pipe with. First shot and after the tubes are trimmed to length, it should fit perfect. I'll make two more from 16ga. 304 stainless without the nasty brake mark notches tomorrow.

 

http://i157.photobucket.com/albums/t55/tinman_015/IMG_1928.jpg

[zeitgeist57]

So...that's where the noise and flames comes out...

[POS VETT]

How does that flat collector compare to the commonly-used "square" collector? It seems to have a volume that's quite large which acts as an expansion chamber. Could it be shaped like a "flat venturi" to reduce turbulence?

 

I must say that I like the top-notch craftmanship. Press on.

[Tinman]

So...that's where the noise and flames comes out...

 

I prefer, music and optically identifiable heat:)

[Tinman]

How does that flat collector compare to the commonly-used "square" collector? It seems to have a volume that's quite large which acts as an expansion chamber. Could it be shaped like a "flat venturi" to reduce turbulence?

 

I must say that I like the top-notch craftmanship. Press on.

 

Thanks.

 

The internal volume of the collector is very close to a stacked or square collector, maybe 5-10% larger but that should work to it's favor as there is an increase in surface area that would cause a little slow to the flow.

[C-Mart]

This is amazing.

 

And my M3 deserves this.

[Mr. Jones]

Wow!

 

Blown away, just incredible.

[Tinman]

Merge collectors near done. I'll have to wait to weld the seams in the oval megaphone until the next section is at least tacked on to prevent tear dropping the seams. My desk job is taking a toll on my welding. Not a lot of torch time in the past 5 years and I'm a bit rusty, but it's coming back.

 

http://i157.photobucket.com/albums/t55/tinman_015/IMG_1933.jpg

 

http://i157.photobucket.com/albums/t55/tinman_015/IMG_1932.jpg

[99StockGT]

My desk job is taking a toll on my welding. Not a lot of torch time in the past 5 years and I'm a bit rusty, but it's coming back.

 

 

Yet still has welds that look better than 90% of "mechanics" and automotive quick stop shops.

 

Keep up the awesome artwork!

[Tinman]

No one makes a 3 1/2" x 2 1/8" oval to 2 3/4" round transition let alone one flat on two sides. So, sheet metal, portaband, 4 1/2" angle grinder and press brake go to work.

 

Tacked up and ready to weld to the oval mandrel bends that begin the transition from stacked collectors to side by side pipes that will then transition to the X pipe.

 

http://i157.photobucket.com/albums/t55/tinman_015/IMG_1934.jpg

 

If anyone reading this is understanding how this will happen, I feel for you because your mind might be as twisted as mine. For those that have no idea what is about to happen, good for you. It shall become clear soon.

[zeitgeist57]

Jesus...

 

Christ.

[Cordell]

I was picturing a twisted x-pipe, but I look forward to seeing more of your progress. Still excited to hear it.

[POS VETT]

No one makes a 3 1/2" x 2 1/8" oval to 2 3/4" round transition let alone one flat on two sides. So, sheet metal, portaband, 4 1/2" angle grinder and press brake go to work.

 

Tacked up and ready to weld to the oval mandrel bends that begin the transition from stacked collectors to side by side pipes that will then transition to the X pipe.

 

http://i157.photobucket.com/albums/t55/tinman_015/IMG_1934.jpg

 

If anyone reading this is understanding how this will happen, I feel for you because your mind might be as twisted as mine. For those that have no idea what is about to happen, good for you. It shall become clear soon.

 

That's exactly what I was talking about, a "flat venturi" for lack of a better term.

[Tinman]

I was picturing a twisted x-pipe, but I look forward to seeing more of your progress. Still excited to hear it.

 

That was my initial idea as well but it would have caused two issues. First, I would be locked into that particular X pipe and I want to experiment with different styles of X pipes in the future so I want the collector section of the exhaust to end in two flanges so different X pipes can be fabbed and installed without changes to the system beyond the X. Secondly, it would mean tying all 8 cylinders into a large section that would make it difficult to make a 8 slip fit sections at once. By going a different route, I will be able to make four slip fit connections at a time, hopefully making install and future work on the car easier.

 

The twisted X pipe will still exist as plan B and the way this is going, I may need a longer alphabet to label all the plans needed.

[Tinman]

A little more progress,

 

http://i157.photobucket.com/albums/t55/tinman_015/IMG_1946.jpg

 

http://i157.photobucket.com/albums/t55/tinman_015/IMG_1949.jpg

 

http://i157.photobucket.com/albums/t55/tinman_015/IMG_1947.jpg

 

I was worried about ground clearance with the stacked pipes but all looks to be okay. They lower pipe is level with the seat rail brackets, slightly lower than the floor itself.

 

http://i157.photobucket.com/albums/t55/tinman_015/IMG_1951.jpg

 

Back to the bench to get the side by side action happening. Beer can bottoms make excellent purge caps.

 

http://i157.photobucket.com/albums/t55/tinman_015/IMG_1957.jpg

 

I should have this section of the exhaust complete by the end of the weekend and finally be back to square 1.

[Forrest Gump 9]

Those ^^^^ look amazing

[Jelloman4571647545499]

Looks awesome Matt. Still the Champ!

[caseyctsv]

Artwork! About there being more room on a Camaro...I may know a guy who would

Be interested in your services

[Cordell]

So when these are done I'm going to steal your Corvette long enough to remove these and swap them with my store bought headers, okay? sweet.

[Tinman]

Those ^^^^ look amazing

 

Looks awesome Matt. Still the Champ!

 

Thanks gents.

 

Artwork! About there being more room on a Camaro...I may know a guy who would

Be interested in your services

 

Appreciated but, with the Camaro's transmission being located in the front, the primaries would have to be at least 5' long and performance would suffer greatly.

 

So when these are done I'm going to steal your Corvette long enough to remove these and swap them with my store bought headers, okay? sweet.

 

Return it with an LS7 between your store bought headers and you have deal.

[caseyctsv]

Who needs a transmission if it will sound like that? Really cool stuff - cannot wait to see the finished product

[Cordell]

So I'm curious how much thought you've put into the oxygen sensors? I would suppose bank 1 and bank 2 would still work relatively well unless there is a cylinder imbalance. The ECM would continue to make adjustments without results until fuel trims are maxed out. I suppose changing the computer to stay in open loop might be the simplest way to prevent issues.