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Old 07-28-2007, 01:36 AM   #36
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Join Date: Sep 2004
Fan#: 12724
Location: Fairmont, WV
What I Drive: Turbo 04 DSG Mach 1

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Day 11

Start time: ~7:00pm
End time: ~1:30am

Well I was hoping to finish up the exhaust today, but I'll have to finish up tomorrow.
My plan was to just work through the night but I'm too tired.
I have most of it done, just the last angle left to do and then fully weld the tack welds.
Since I'm using flux core wire I'll be painting the exhaust, even though most of it is stainless steel.
The "tip" will not be painted, but instead I used the wire wheel on my bench grinder to polish it.

The exhaust is completely from scratch..
The mandrel bends are "seconds" from
They sell seconds for $5/bend for aluminized or $7/bend for stainless steel.
Don't take this price as gospel though. If they change it they change it.
All of the hangers I'm having to fab too.
It would have been far easier to purchase a cat back, but if you haven't noticed I'm a bit stubborn like that.

I plugged the hole in the EVO section of my air intake.
A cap from a mini can of WD-40 fit absolutely perfect.
Hey, sometimes you have to improvise! :)

Not many pics today..


WD-40 cap in intake:


Polished but dirty stainless steel "tip":
3" is plenty big enough of an exhaust tip.

1 of 5 custom hangers I have to make:
I'm using a 3' section of 3/8" round steel that I cut into pieces.
So far it's working great, but tedious work.

Goals tomorrow:
- Finish exhaust
- Assemble turbo
- Run oil lines
- Clamp intercooler piping

- Coolant lines to turbo
- Install gauges
- Load base tune
- Other stuff I've forgotten about

An ambitious schedule for sure!
I really want my car on the road Monday, and tuned Friday.
For now, I need sleep!!
'04 Mach 1. Built. Turbo. 667whp/631wtq
'06 Focus. Built. Turbo. WMI. (sold)
'03 Mach 1 : 12.61 @ 106.59 (sold)

Last edited by sutyak; 09-05-2007 at 10:10 AM.
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