Garrett Powered Posted September 1, 2009 Report Share Posted September 1, 2009 I have tgp cast aluminum tips I cut off and want to use on my 2.5" catback. I want to cut them open and attach them to my mufflerless exhaust in a way so they are not restricting flow. they have a small opening on them though, less than 2" out the muffler. has anybody done this with any success, and how did you attach the two pieces? drill holes and screw together or clamp? I can imagine the end of the exhaust pipe must be bent into an oval shape to fit in the end. It looks like it would just barely fit though if I port the tip out just right. I would be stoked if I could avoid buying exhaust tips. Quote Link to comment Share on other sites More sharing options...
White93z34 Posted September 1, 2009 Report Share Posted September 1, 2009 considering out dual exhaust is fake anyhow you aren't really restricting much (if at all) by using both tips as is 1.25+1.25=2.5. It should be the same as just running a single 2.5 outlet rather then 2. IF it restricts any, its not gona be much, Quote Link to comment Share on other sites More sharing options...
RobertISaar Posted September 1, 2009 Report Share Posted September 1, 2009 considering out dual exhaust is fake anyhow you aren't really restricting much (if at all) by using both tips as is 1.25+1.25=2.5. It should be the same as just running a single 2.5 outlet rather then 2. IF it restricts any, its not gona be much, are you saying a 2 1.25 inch diameter tubes flow the same as a 2.5? Quote Link to comment Share on other sites More sharing options...
GOT2B GM Posted September 1, 2009 Report Share Posted September 1, 2009 considering out dual exhaust is fake anyhow you aren't really restricting much (if at all) by using both tips as is 1.25+1.25=2.5. It should be the same as just running a single 2.5 outlet rather then 2. IF it restricts any, its not gona be much, Area of a circle = pie X (r x r) = 3.1416 x (0.625 x 0.625) = 3.1416 x 0.390625 = 1.227 sq inches of area for one 1.25" diameter pipe = 2.4544 sq inches of area for two 1.25" diameter pipes Area of a circle = pie X (r x r) = 3.1416 x (1.25 x 1.25) = 3.1416 x (1.5625) = 4.90875 sq inches of area for one 2.5" diameter pipe Quote Link to comment Share on other sites More sharing options...
RobertISaar Posted September 1, 2009 Report Share Posted September 1, 2009 exactly what i was getting at. you need 4 of the smaller tubes to equal the one larger one... Quote Link to comment Share on other sites More sharing options...
GOT2B GM Posted September 1, 2009 Report Share Posted September 1, 2009 Oh and to answer your question Garrett, I plan to cut the restrictive 2" OD neck off of my tips when I install my exhaust, and buy some 2.5" OD aluminum tubing, and have my cousin TIG weld it up to the cast aluminum tips. Then using a die grinder, I will "port" the inside of the tip to match the inside radius of the 2.5" OD aluminum tubing. The 2.5" OD aluminum tubing will slide into the 2.5" ID SS exhaust piping just like stock and clamp on. I plan to taper the leading edge of the aluminum tubing to cause less turbulence when the exhaust hits the little lip between the SS and the aluminum. Quote Link to comment Share on other sites More sharing options...
White93z34 Posted September 1, 2009 Report Share Posted September 1, 2009 Okay. All the smart people schooled me here. Quote Link to comment Share on other sites More sharing options...
mfewtrail Posted September 1, 2009 Report Share Posted September 1, 2009 I simply used an adapter for my stock tips...so I still have the tiny outlets. I'm going to install aftermarket exhaust tips sometime soon though. Based on the fact that Josh's(RIP ) turbo cutlass put down 260whp with a stock TSTE exhaust(minus the cat), the stock tips can't be much of a restriction. At stock turbo power levels, the exhaust isn't as much as a restriction as people think...but uncorking it some would surely help. Quote Link to comment Share on other sites More sharing options...
Garrett Powered Posted September 1, 2009 Author Report Share Posted September 1, 2009 well I decided to uncork mine the aluminum pipe I got is the same 2.5 ID as the rest so I should be able to just use my harbor freight tailpipe expander on my exhaust and slide in the aluminum tip and clamp. the aluminum shaped nicely though and fits snug in the tip, I don't even have to use a worm gear clamp like I was planning to hold it together to weld! kind of turned out to be easier to do than I expected and I can port it out and smooth the inside once they lay the weld for a finished look. I am going to make some steel ones too for my 3" system now since the steel yard cut these for me @$0.35/#+$5/cut. Quote Link to comment Share on other sites More sharing options...
Garrett Powered Posted September 2, 2009 Author Report Share Posted September 2, 2009 will they be able to weld in these gaps? I got a little aggressive with the cut off wheel. this is what I came up with after my attempt in trying to get this ready for the welder. I will take them down tomorrow afternoon and have them welded up. Quote Link to comment Share on other sites More sharing options...
Garrett Powered Posted September 2, 2009 Author Report Share Posted September 2, 2009 Okay. All the smart people schooled me here. thats what I am hoping happens to me here. Quote Link to comment Share on other sites More sharing options...
Garrett Powered Posted September 4, 2009 Author Report Share Posted September 4, 2009 got it done and here are pics of them. I have to go smooth out the welds with a wire wheel, but they look good already if you ask me. decent quality welds but I had to pay for it. It ended up being $65 for the welds and he cut and bent a piece of their thick walled 2.5" pipe for me for my down pipe. Quote Link to comment Share on other sites More sharing options...
Mach 5 Posted September 4, 2009 Report Share Posted September 4, 2009 thats awesome! Quote Link to comment Share on other sites More sharing options...
Garrett Powered Posted September 4, 2009 Author Report Share Posted September 4, 2009 whoa! I picked up this wire wheel for my grinder and it took them down to bare aluminum in like 5 minutes each! then I took my DA to it with 220 and 320 grit and they came out awesome. I will wet sand them later I am too tired from it already. I will try to shape that one side more oval too. Quote Link to comment Share on other sites More sharing options...
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