3rd Gen. True Dual Exhaust Build

Just wanted to share my exhaust build in its own thread vs posting updates on the Ov TT thread.

Reason why I decided to do this was to get rid of the stock exhaust in preparation for the twin turbo kit (PowerMax, full fuel upgrades) to improve flow and sound and learn something new. In my opinion the stock exhaust has several limitations, from inadequate pipe IDs and bends, to unequal y pipe lengths (for sound).

I decided on a dual 2-1/2” exhaust after reading and watching videos on different V6 twin turbo setups. The original plan was a divorced system, but settled on a X pipe design to incorporate a cutout. In the end my goal was to have a flow through system that was quiet when needed, no drone, no rasp, no pops/bangs and made to last.

Parts (all 304 SS):

2 bolt flange: Amazon, 2.5” Stainless Bros 603-06320-0000
Gasket: Amazon, HYCC 2-Bolt 2.5''
Exhaust pipe: Amazon, Squirrelly 2.5" universal kit 16 ga - SPP FABKIT-5
Resonator: Amazon,Vibrant Ultra Quiet - 1141
Muffler: Amazon, Borla ProXS - 400286
Cutout: Amazon, Keenso 3” vacuum activated, normally closed - Keensogbwoqer15z-02
O2 bung: eBay, fab-pro notched
V-bands: eBay, Yonaka YMVBFC25
Over axle mandrel bend: eBay, PLM U L J (didn’t use most of it, would not do this again).
2.5 to 3” transition: eBay, fab-pros
3” pipe for cutout turndown: eBay, khaos-Motorsports 90 short
Exhaust tips: eBay, catinbow 2.5” to 3” double walk angled (cut off)
Hangers: eBay, Yonaka 1/2”x9.5”

Welder and parts: Amico TIG-225 that I modded for pre/post flow control, variable pulse, tack mode and foot pedal. CK worldwide 17 torch, Furick FUPA #12, .045/1/16” 308L filler, 3/32 blue electrode.

Weld settings: 100% back purged @ 5-10 cfh, torch mostly at 20-25 cfh. Pipe to pipe with bad fit up, 55 amps (w/foot pedal) .045 filler. Pipe to pipe with good fit, 1.5 pps, 25% peak, 55 amp peak, 10% background amps, autogenous (no filler). Flanges were done mostly with the same pulse settings @ higher amperages with 1/16 filler.

Band saw: Amazon, 4”x6” WEN 3970 T w/ starrett blade

I had no previous experience doing this, just watched videos (kudos to Jody, weldingtipsandtricks YouTube channel) and learned as I went. I took time to practice and hoped for the best both in fabbing and what it would sound like.

A few pictures, feel free to ask any questions. I will do my best to answer.

Started with X pipe, from 2 U-bends cut at 30% ID and 45 degrees:


Then added a 90 using pie cuts (9+9 degree, short radius).


Fabbed left and right sides, which replaced the secondary cats with vibrant resonators. Left side is a 55 degree offset of center, right side is 45 degrees.



Added v band flanges to X pipe and welded it up:



3” cutout parts (pie cuts 9+9 degree):





All fitted and checked for clearance:


Welded O2 bungs and finished welding both sides:



Placed the Borla muffler as high as I could:





Added hangers (stock locations):


On to the most challenging piece! Took 41 pie cuts and lots of time. I wanted to be able to fit a 33” spare (move bracket) and allow full droop (RXT + ext. length FOX 2.5), I still want to fab a turn down that can be swapped when needed. I’m changing the hangers to BAMF as well.



Onto the exit, I wanted the tips to be as high as possible for looks with enough clearance. I had to move the hanger further up as well.




Here is the sound clip of a warm start, revs to 4-6k. Ov 2.0 tune. No other mods, stock air box. Overall I’m very pleased with the tone and volume, no rasp what so ever, no drone and quiet when needed. My calibrated butt dyno (not) tells me there is a perfomance improvement. The truck feels more lively on low RPM for sure, more noticeable up top, which is surprising given the pipe diameter.

https://vimeo.com/459999807

I still need to hook up the cutout, which will give the tone a bit more of an attitude. The truck is back in the basement for other mods prior to the twin turbo install, which hopefully will happen by mid October. I’m expecting the exhaust tone to change a bit with TT’s (catted down pipes) and be a bit quieter because of the turbos. I’ll update as the install moves along.

 

Excellent craftsmanship! Good job man!

 

highest compliments. i just love this kind of work. can't wait for the sound clips!

 

Incredible work man. Looks and sounds amazing!

 

that was weird, that clip didn't show, but i was on H+ with poor signal. sounds pretty great, surprisingly mellow.

 

Wow, that is crazy nice! Kudos to you brother. Enjoy the fruits of your labor on this one.

 

Its a true work of art!! WOW great job

 

I'm very impressed. Looks wicked.

 

Skills ! Sounds great too

 

Yeah, that's some serious welding skill.

 

clean setup

 

Good Lord. That is beautiful!

 

Hell yeah! Glad u made a thread. How long have u been Welding? Those welds are damn near perfect. No undercut on the flanges! If u have a CAD of this you should look into someone making this exhaust, I have no idea what that entails or how expensive it would be but I'm sure you'd sell these as a kit if they were on the upper end of reasonable.

 

You sir, are a artist.
That is amazing.

 

Am I reading right that this is your first time welding??? I've seen professional welders who can't do that. Incredible work!

 

Thank you all for the compliments. I really had a blast making it and wanted to share with anybody that wants to do the same. I took a welding class in college (engineering) about 10 years ago and wanted to get back into it, this was the perfect excuse.

I would be more than glad to help someone out with dimensions and what not, or put it in CAD but don’t think this would be something ppl would jump on to buy though. I may be wrong.

 

This looks awesome! Amazing welding too

Any inside sound clips?

 

That's bas ass, nice work!

 

In this picture, what is that connection between both sides for? The section just in front of the actual muffler, where you welded both pipes together with some kind of dump pipe.

 

I did record this, sounds better with headphones.

https://vimeo.com/461194737