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  #1  
Old 05-22-2005, 10:59 PM
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Welded the new exhaust

Finally finished welding up my new exhaust - from turbo to tail. The pipe and mounting hardware is all 2 1/2 16 gauge 304 stainless steel (non-magnetic). I used a Magnaflo straight through muffler, but it is a 400 series stainless (magnetic). I got the mounting hardware from a metal scrap yard when on some business travel for a whopping $12 - Strange sort of paddle for a massive kitchen soup bowl, such as you would find on an aircraft carrier. Unfortunately it was too long for my suit case, so I stopped by Walmart and bought a hack saw, rubber gloves, and shop towels (it was dirty). I cut the pieces in the parking lot, shoved everything in the suit case, and then when to the airport to catch my flight. Boy did TSA have a field day! but the is another story . . . .

I used the shafts of the paddles for a support where the resonator used to be. I had to bend and weld many of the pieces. The pictures pretty much speak for themselves. I had to cut them down to meet the >65KB file attachment size restriction.

The flare at the turbo was tricky. That is the only place where I used a piece of the original system - all of about one inch. The way the flare is made it is already wider. I tried pounding out some of the 16 gauge 304, but it was too thick.

Attached Thumbnails
Welded the new exhaust-dscf1061d.jpg   Welded the new exhaust-dscf1030a.jpg   Welded the new exhaust-dscf1062a.jpg   Welded the new exhaust-dscf1059a.jpg   Welded the new exhaust-dscf1060a.jpg  

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  #2  
Old 05-22-2005, 11:14 PM
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More Pics
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Welded the new exhaust-dscf1029c.jpg   Welded the new exhaust-dscf1029d.jpg   Welded the new exhaust-dscf1036b.jpg   Welded the new exhaust-dscf1036c.jpg   Welded the new exhaust-dscf1065a.jpg  

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Peach Parts W124.128 User Group.

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  #3  
Old 05-22-2005, 11:19 PM
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Nice looking work........if and when I do mine I will use 3" stainless...I need to acquire a means to weld stainless first however.
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1971 280SE W108
1979 300SD W116
1983 300D W123
1975 Ironhead Sportster chopper
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Old 05-22-2005, 11:20 PM
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Well drop by. We're only one zip code apart. I learned quite a bit doing it.
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Peach Parts W124.128 User Group.

80 280SL
85 300SD
87 300TD
90 300TE 4Matic
90 300D 2.5 Turbo
92 300D 2.5 Turbo
92 300TE 4Matic
01 Saab 9-5 Wagon
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  #5  
Old 05-22-2005, 11:22 PM
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Quote:
Originally Posted by pwogaman
Well drop by. We're only one zip code apart. I learned quite a bit doing it.
PM me...I'd like to see this work one day....
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1971 280SE W108
1979 300SD W116
1983 300D W123
1975 Ironhead Sportster chopper
1987 GMC 3/4 ton 4X4 Diesel
1989 Honda Civic (Heavily modified)
---------------------
Section 609 MVAC Certified
---------------------
"He who fights with monsters might take care lest he thereby become a monster. And if you gaze for long into an abyss, the abyss gazes also into you." - Friedrich Nietzsche
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Old 05-22-2005, 11:39 PM
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Even more pics . . . Too bad we can't load larger pictures
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Welded the new exhaust-dscf1037a.jpg   Welded the new exhaust-dscf1037b.jpg   Welded the new exhaust-dscf1037c.jpg   Welded the new exhaust-dscf1037d.jpg  
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Old 05-23-2005, 12:25 AM
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What type of welder did you use, and where did you get the flexible section of downpipe?
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Old 05-23-2005, 01:03 AM
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The welder is a Lincoln Electric SP135 (110 volts). I got the flex pipe from J.C. Whitney. While the flexible parts are 304, the ends are "plated" mild steel. Not exactly what I wanted, but once I got it I didn't want to mess with returning it and looking for another.
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  #9  
Old 05-23-2005, 01:18 AM
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Quote:
Originally Posted by pwogaman
The welder is a Lincoln Electric SP135 (110 volts). I got the flex pipe from J.C. Whitney. While the flexible parts are 304, the ends are "plated" mild steel. Not exactly what I wanted, but once I got it I didn't want to mess with returning it and looking for another.
Well whuddya know, I have the exact same welder. Anything I should know about welding SS, and joints between SS and mild steel?

Good to hear flexible pipes are out there for DIY projects.
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  #10  
Old 05-23-2005, 01:31 AM
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Nice job

I was thinking about it for my 300TD.
1) what is the difference in road noise when you go 70MPH?
2) Did you measure the temperature difference (i.e. before and after) ? I was wondering if the better flow of air from the turbo on will decrease the temp.
3) do you have any difference with milage ?

Thanks and again great job
Yossi
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  #11  
Old 05-23-2005, 11:03 AM
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Too soon to realize and results. I'm still working on replacing the rear 1/3 of the right quarter panel lower extension because of a spot of rust (okay, a 4 inch hole). Once I get another installment of tools from Harborfreight I'll finish that up and be able to put the rear bumper back on and try it at speed on the road. In the mean time I don't want the grinded paint free metal out of the garage - except to test the muffler.

As far as the SS welding: When mating 304 to 304, you need to use 308 wire. When mating 304 to 400 series or mild steel, you need to use 309L wire. I also used a 75% argon / 25% CO2 gas mix. You really can't use the flux core / gasless wire if you have to make multiple passes, and unless your welding is perfect and you can perfectly cut your pipe pieces, you will be making multiple passes. I think I burned through about 4 times and had to build up from the sides of the hole. Overall, I am not worried about the structural intergrety because I'm using 16 gauge and so much more of the joint weld seam was without any problem. I've read that it is best to back fill the pipes with the shielding gas, or to use brush on flux. I did neither and I believe the welds will hold. If they don't, I still have a welder with which to fix it.
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  #12  
Old 05-23-2005, 08:41 PM
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Looks like you used some generic figure 8 rubber hangers where the resonator used to be. Where and what exactly did you attach your hanger to? I can't tell from the picture. I removed my rusted resonator and replaced with a piece of straight pipe and it's hanging low. Would like to copy that bit.
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Old 08-05-2005, 01:59 PM
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Quote:
Originally Posted by yshahar
I was thinking about it for my 300TD.
1) what is the difference in road noise when you go 70MPH?
2) Did you measure the temperature difference (i.e. before and after) ? I was wondering if the better flow of air from the turbo on will decrease the temp.
3) do you have any difference with milage ?

Thanks and again great job
Yossi
I've got a couple of hundred miles on the exhaust now, so I believe I'm in a better position to answer your questions.

1 - Hardly noticeable at all. If the radio is on, which it is all the time, I can't tell the difference. Let me qualify that response though - the before against which I am judging the after was an exhaust system full of holes.

2 - No I didn't measure the difference before and after - except I can tell you that spitting on the hot pipe will sizzle and stink just the same. A strickly non-scientific measurement.

3 - I have noticed a lot better mileage, but again I must qualify that response. The before had an increadibly clogged tank filter (see my other posts) and the majority of the after from which I am making my assessment was without a functioning a/c compressor clutch (again, see my other posts).

I have noticed a lot better performance and would do it again in a heart beat.

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