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Homemade 3" Turbo Back Exhaust


Hilton

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As some of you know, the head gasket on my 1997 Volvo 850 GLT failed. Some may say that the ~15psi of boost I was able to give it after swapping in a ported 15G had something to do with it. Those people are LIARS! It was destined to happen, I read it on a fortune cookie.

As the car was down ANYWAY, it seemed like a good time to build an exhaust. A friend of mine (Galen on the F-Body boards) acquired a BUNCH of 3" pipe, much of it mandrel bent to various angles. He also supplied the muffler which originally was on a Dodge truck (the Hemi, not the turbo diesel).

After removing the stock exhaust and laughing a little, we began. First we welded up the downpipe.

downpipeA.jpg

downpipeB.jpg

downpipeC.jpg

oh good, it fits

downprepaint.jpg

Then we welded the next part going to the muffler.

flextomuffler.jpg

flexbackprepaint.jpg

lengthprepaint.jpg

mufflertosignatureprepaint.jpg

slipjointprepaint.jpg

tipprepaint.jpg

Gotta take credit for it, right?

signatureprepaint.jpg

After much cleanup with a 3" wire wheel, it was time to start painting!

freshpaint.jpg

mufflerpainted.jpg

mufflerfrontpainted.jpg

Then we put it on the car.

downinstalled.jpg

downinstalledb.jpg

flex.jpg

Mufflerhung.jpg

rearhanger.jpg

underA.jpg

underB.jpg

underC.jpg

Not nearly as much beer was drank during the building of this exhaust as you would think.

Comments are welcomed!

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looks pretty good for a quick fix, unless its gonna stay in.

Uh, huh? Why would it be bad to stay in? It's an exhaust. They're round (sometimes oval) tubing that routes waste gases from your vehicle onto unsuspecting pedestrians. I see no reason that that exhaust isn't as good (or better) than all the shiny ones that you pay top dollar for.

Hilton: What did you paint it with?

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Uh, huh? Why would it be bad to stay in? It's an exhaust. They're round (sometimes oval) tubing that routes waste gases from your vehicle onto unsuspecting pedestrians. I see no reason that that exhaust isn't as good (or better) than all the shiny ones that you pay top dollar for.

Hilton: What did you paint it with?

Most def. not better. Quality speaks money.

Looks nice hilton.

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My T5 Sounded like a V8 w/ dropped headers with just the single Borla muffler. :blink:

Mine is so quiet (at idle/cruising) with the single Supersprint muffler... I like it, but I would also love a 3" straight pipe all the way to the rear bumper for shits and giggles :lol: Fireballs anyone?

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Mine is so quiet (at idle/cruising) with the single Supersprint muffler... I like it, but I would also love a 3" straight pipe all the way to the rear bumper for I crapped my pants and I love how it feels and giggles :lol: Fireballs anyone?

Agreed,

My S60R has a single muffler and it sounds very good - barely noticable at idle. It's amazing how quiet these cars really are!

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Thanks guys. It took a lot longer than we thought it would, but I'm really happy with it.

The muffler is straight through. Dumb luck. I didn't know that it was important.

I painted it with high temp BBQ grill paint. It's supposed to be good up to 1200 degrees. It'll either work, or it won't.

It's staying in. I'm really proud of it. It took a lot of measuring, cutting, tacking, testing, cutting again, tacking, testing, then welding. I guess welding is like anything else in that the more of it you do, the better you get at it. This was my first real welding project.

I don't think it's going to leak anywhere. I prepped both sides really well with a grinder and then welded the pieces together. If it does leak anywhere, I'll pull it off and fix it.

I left off my favorite part of the project. Total cost

flex pipe $38 shipped eBay

pipe free Galen already had it

muffler free Galen already had it

O2 bung free Galen already had it

paint $9 Advanced Auto

flange $2.50 Summit (bought months ago)

2 clamps $5 Advanced Auto

Tip free I already had it

gasket free I already had it

I'll be happy to post sound clips once the engine is back together.

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