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Old 07-28-2007, 01:36 AM   #36
sporadic
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Join Date: Sep 2004
Fan#: 12724
Location: Fairmont, WV
What I Drive: 06 Sonic Blue ZX5 SES turbo

Posts: 1,260
FF Reputation: 61 sporadic Excellent Standing Member
Buy-Sell-Trade Rating: (12)
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 www.mandrelbendingsolutions.com.
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..

PICS

WD-40 cap in intake:


Exhaust:


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

Sunday:
- 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!!
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2006 sonic blue zx5 GT2871r turbo.

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