Exhaust, can anyone help ?

[wylliezx9r]

Hi everyone,

I'm at the point in my build where I need the exhaust manifold and system fabricated. My car has a zx9r engine fitted so there is not an off the shelf system that will fit.

My ideal solution would be that a fabricator could come to my place and do the work there. The reason being I will have to hire a trailer (nearest place 25 miles away, cost of £200) and then take the car to the nearest place. I realise that it is very unlikely to be someone in my area who would be able to do this or is there?

Another idea is that I could knock something up on CAD and maybe a fabricator could use this to create the system, I dont know if anybody does this?

So my question is where is the best place to take it/or any other ideas? I am located in Blackwood South Wales about 25 mins from Newport if anyone knows the area ?

Many Thanks

Dan

[michael92]

I would jump at this chance I you was closer! As I'm nearly 150/200 miles opposite side haha. I personally would just get stuck in , would be a great learning curve I can find all the formulas you would need if you like or even help you calculate them myself :) That's if you have a performance manifold in mind?

Michael

[wylliezx9r]

I would jump at this chance I you was closer! As I'm nearly 150/200 miles opposite side haha. I personally would just get stuck in , would be a great learning curve I can find all the formulas you would need if you like or even help you calculate them myself :) That's if you have a performance manifold in mind?

Michael
Yeh mte it's a pity you are so far away, doh :mad:
In regards to manufacturing it myself Im an electrician by trade and have little fabrication experience and dont want to make a mess of it (am i just being a scary cat ?). Also have been looking at the prices of manifold collectors and stuff (there is not a lot available} and couldnt beleive the prices it made my eyes water :D Do you happen to know where the parts that make up the system could be purchased at a reasonable price?

In terms of the formulas for calculating the lengths etc that would be great if I do have to go down the road of making it myself.

cheers Dan

[michael92]

http://cgi.ebay.co.uk/90-degree-Stainless-Exhaust-Mandrel-Bend-63mm-2-5-inch-/220757858261?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item33663197d5

http://cgi.ebay.co.uk/45-degree-Exhaust-Mandrel-Bend-Stainless-76mm-3-inch-/220757039804?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item3366251abc

http://cgi.ebay.co.uk/90-degree-Stainless-Tight-Radius-Mandrel-Bend-2-5-63mm-/320578676355?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item4aa3fa6683

There are a few things that you will/may need although they are in stainless, stainless is nice! but rather expensive and im guessing if you dont want to fabricate you certainly dont want to be welding £50 worth of a bend!

if you slap in on google exhaust components a few companies will pop up that will give you a rough guide . and even linco stock parts which i found out :P.

i will find you the company i use there on my emails somewhere ;-) got to trail through 100 or so emails haha !

they will usually do a good deal on a bulk buy kind of thing :cool:
and certainly much cheaper than other places :D

Michael

[Talonmotorsport]

I've just looked at the standard steel manifold on ebay, I would say have a go at doing it on the cheap and buy a second hand one. Cut 3-4 inches out of the middle of the down pipes and turn the collector round the other way then weld a 80' bend on the end of it to point down the side of the car.
I know stainless looks good but stainless manifolds crack after awhile if not done properly.

[MarkB]

Buy a race pipe for the ZX9 motor then use the manifold as it is but extend the pipe after the headers to allow the silencer to run down the drivers side...all you will need is one bend and a bit of pipe....simples and I did the very same on my daft Lotus 11 thing a few years ago....
I'm in cornwall if you fancy dragging it this far? maybe even Plymouth?

[michael92]

as talon says, stainless looks nice but same gas speeds can be acchived with a well designed steel manifold with heat wrap , s'all about the gas flow baby :p id get stuck in!

as otheres have said also i too am getting the original manifold and cutting the flange of and making it up off that .

[wylliezx9r]

Thanks for all the advice lads its much appreciated :) im going to bite the bullet and have a go at making one myself. I've already sourced a bike manifold and im picking it up from a local breakers, so will be making a start tomorrow :) my mate has also got a manifold that looks like its off a kit car of unknown origin, maybe I can cobble them together. If the result is good, i'll post up some piccies, if its bad i'll keep them to myself lol.

Again many thanks for all the advice

Dan

[ozzy1]

Bit late but Formula 27 used to do an exhaust for their zx9r powered 7.It exited on the drivers side though.From memory the manifold was around 200quid and the silencer about the same without a cat.
Formula 27 now owned by YKC from what i recall.

[MarkB]

Bit late but Formula 27 used to do an exhaust for their zx9r powered 7.It exited on the drivers side though.From memory the manifold was around 200quid and the silencer about the same without a cat.
Formula 27 now owned by YKC from what i recall.

Both long since gone, The F27 has been dormant for years.

[shh120m]

iv just cut and shut my cbr1100 manifold with the same diameter pipe, the only problem i had was flushing the welds on the manifold as it was hard to get a grinder between each pipe so i did it with a dremel and it took me all day! It doesnt look a million dollars, but it does the job. I intend to get someone to put it right once the cars on the road and funds allow.

[wylliezx9r]

Well guys, just thought I would show you the result of my weekends work. It isn't perfect the collector is pointing up slightly and is about halfway up the side panel, I would have preferred it to be lower, I can sort this imperfection with a slight bend in the pipe that will go to the cat and eventually can. In all though I've saved about 600 quid :D. Which is always nice, especially since im skint (holiday to Jamaica to pay for).
On a side note I also have the boss for the lamda sensor to block off, would any body happen to know what size bolt I require, I believe its standard on most cars?

Cheers Dan

http://i1099.photobucket.com/albums/g400/danielburberry/IMAG0216.jpg

[michael92]

yeah! top notch geeza!

i love exhaust porn haha :p

but seriously thats cool :)

[monsterob]

nice job ! fancy a crack at mine ? lol

im still struggling to collect parts for my exhaust but not ready for one yet so ho hum :)

[wylliezx9r]

nice job ! fancy a crack at mine ? lol

im still struggling to collect parts for my exhaust but not ready for one yet so ho hum :)

Pure luck mate, was lucky that exhaust I picked up wasn't far off, if you look just below top chassis tube you can see all the weld marks, luckily they will be hidden by the side panel. I also welded stainless to mild, so I don't know how the welds will last:confused:
I can't believe the price of exhaust parts especially collectors:eek:

[davidimurray]

On a side note I also have the boss for the lamda sensor to block off, would any body happen to know what size bolt I require, I believe its standard on most cars?

Normally M18 x 1.5 - http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=160587092584