I am building a completely custom TBE exhaust for my 07 sti and just thought I would share the progress with you guys. I just recieved the DP flanges today. I actually laid out the placement of the holes exactly where "I" wanted them. I think the only significant change I made compared to a standard divorced downpipe is that my holes are very close together. Reason for this is I made my wastegate hole perfectly centered of the WG flapper. The other guys leave a bigger gap by far between the two holes and that bothered me because there is no way it could be centered over the WG. If you have any questions feel free to ask I will keep updating as progress continues. I had two flanges made in case I make a mistake or I decide that I want to build a 4 inch for comparison.





01\02\08

Few more parts. This is a random assortment of parts I picked up to get started. If I need more I will get more or take back what I do not use. All I need to get started is my straight pipe which I will be getting in the morning before work and then my argon tank and stuff to cut with and I will be on my ay to finally starting this. Work has been sending me out of town alot and then when I am in town it seems that overtime comes up so its been a pain to get to places to go buy parts. But I should finally get started on it this weekend. Another change of plans for me is to Maybe by the muffler, I was looking around for tube at my work big enough to make it with and we dont really have any thats thin wall like I want and I dont feel like paying out the *** for a stainless piece from a pipeing company when there are several name brand universal mufflers out there. So we will see. If I decide to go that route I will update of course with pics.

 

gl man.. hope it works out!

custom Exhaust FTW

 

I don't mean this a condescending way, but why are you doing this? I'm just curious what the goal of your project is since the market is full of quality choices already.
Unless you wanna be crazy like I was and rock a straight pipe hehe.

 

Somewhat crazy haha. Well for one I want to be unique I want my car to have my exhaust since I know I have the ability to build it. The other is its actually a school project. I am a union sheetmetal apprentice and I turned it in as my project for the year.

 

good luck. Post pictures of how the build is going.

 

Here are pics of my downpipe that I started tonight





These tacks are a little hot but I was not sure how hot I needed to run this 110v miller tig welder I am using to tack it all together but I have it dialed in better now. I am going to use our nice Miller welder with pulse at work for the final weling of everything. It is all stainless by the way some just looks different because some pieces are polished some are unpolished I just am using what ever I can get for free that I can. So far all the straight has been from left overs at work





This is how far I got tonight but that last miter before that long section of straight I am going to move and chance it from a 20 degree offset to somewhere closer to 15 degrees I dont like how close it gets in some areas. That straight will also be shortened to but I just have not cut it down yet to install the cat in that section. More updates this weekend I promise.

 

^ Interesting....

 

not bad man!

 

Ooh, right on then! More power to ya!
Starting to look pretty good!

 

Well here is the downpipe with the cat, o2 bung, and everything else completed. Now its finally time for me to grab a quick bite to eat I have not eaten since I got up and started in it lol. The hard part is out of the way so the rest should go faster. However I am thinking of finishing it out today with no muffler and just making the last part a straight pipe section because I do not have the muffler packing material in from the mail yet and my car has been sitting on jackstands for almost 7 weeks now and I want to drive it so damn bad. Well enjoy these pics for now more to come as soon as I get there hope you like it.

 

very nice work! keep it up bro.

 

Nice job man, I became a pretty passionate hobby welder myself during my last trip to the sand box. How thick is that steel and what power setting were you using? Seems like it'd be pretty unforgiving.

 

cant wait to here it man!

are u gunna coat it??

another divorced wastegate buddy... ull love it

 

Well I am finished for now until the ceramic muffler packing comes in so I can build the muffler but I just tack welded a 45 degree elbow onto the last section for a turn down just to get it running. God is it ever loud haha. I think even with the muffler this is going to be a very loud exhaust. I reved it up just a little and hearing the turbo spinning once you let off the gas sounds so freaking cool. But I ran into another problem. I went to flash stage two before I drove it anywhere and the AP lost communication during the relash so now it sits dead in the water. The AP wants to go into recovery mode and uninstall itself but the car wont go into test mode anymore so it can't communicate with it. I guess I will have to call cobb in the morning and see what they say. Here are soem more pics for now. What a weekend.

 

how do u like it?