rockstar143

iTrader: (6)

I bought my gaskets for my primaries off of amazon.

Yeah, to me, the $10 die grinder is the best investment I ever made. I've cut though some serious stuff with it.

Matt W

Hmm I wasn't aware that they were the same ones, well I already paid him but I am going to order one from my local dealer so I can get it done this weekend.

That way I will have a reference template when I make some of these for someone else after I have my exhaust installed.

Okay, I am picking one up from my local Acura tomorrow, charged me $9.82 lol. Rich only charged $12 for both shipped. Convenience charges...

Also I am cutting the flange using jigsaw and metal cutting blades, I am cutting the holes using a drill press.

I bought some cutting oil, I did alot of reading on cutting oil last night and apparently sulfur based cutting oil is a big no no if the part is going to be welded so I had to order some different mineral based cutting oil from a local industrial supply warehouse.

This is the sulfur based stuff I bought = BAD
This is what I ended up getting from my local warehouse
http://www.grainger.com/Grainger/SPR...ting-Oil-4GUP3

Matt W

Okay so I was wrong on the sulfur based cutting oil apparently chip weld (metal buildup) and welding (MIG TIG) etc are not the same thing lol and I based my whole assumption off of one mans mistaken forum post.

So I will be using the sulfur based stuff because it is actually excellent cutting oil.

Also my tools are coming today so I should have some picture tonight of the flanges without the holes.

oo7spy

I think the idea of drilling before cutting was good advice, but we just learned how your are with advice on forums...

Matt W

Ha this isn't my first time working on something like this.

Drilling before cutting the flanges would be the preferred way if I wasn't using a drill press and I didn't have a good means to clamp the flange.

Heres the problem with that though:
I am using a drill press.
The sheet is 1' x 3' large
The sheet weighs 40-50 pounds

Now here is how it actually is going to work:
Cut the flange.
Clamp the flange to the drill press on top of a block of wood.
Drill the bolt holes.
Use bolts to screw the flange to wood block.
Clamp the wood block to the drill press.
Drill pipe outlet hole using hole saw on drill press. 100 RPM, Constant cutting oil applied.

Now tell me that sounds better than trying to mount a 40-50 pound 1'x'3 sheet of metal somehow onto the drill press on a piece of wood (so I don't cut through the metal press tray) and then trying to get everything precisely aligned for all 4 holes.

And I don't know where that comment came from on taking advice, I ask you guys for a lot of advice, see the thread title "Muffler Suggestions"? I actually used advice from this thread to make decisions on my mufflers and resonators.

oo7spy

The comment came from this.
Sounds like you know what you are doing. Don't forget pics. Got my on this page too.

Matt W

Ah sorry thought you were attacking me saying I don't take advice, completely misread your post, my bad, almost got the first flange cut btw

Matt W

Gahhhh whoever told me to get the gaskets from Honda/Acura. I though they would be the same ones for the RL so I had them order them in and they were just little o-rings....

Also here is the pictures from doing the flanges, PAIN THE ASS, my first one was too small, the other two I will use a grind wheel on too get them perfect.






FUCK I wish I would have just bought those test pipes now.....

253RL

^damn.

HEAVY_RL

iTrader: (1)

shit jus got real

Matt W

My friend has a plasma cutter! Going to his house today to cut a crap ton of these out.

Matt W

Okay so I grinded the ones I had to size and punched the spots for the holes, I am going to my friends house to use his drill press now, we will polish and smooth the metal out afterwards

Matt W

Flanges are done, here is me cutting the final hole...I do not suggest you do this unless you have patience, know what you are doing, and can't afford to get these custom cut...


The holes may look like they are off but It is because I left a little slack on the side of some just incase.

MrKev

wow looks pretty good, props for having the time and effort in making your own flanges lol

oo7spy

+1.

Matt W

More pictures

If I may say so, I think I did a pretty good damn job, Look how nicely that pipe fits into the flange.

Well now I have everything but the gaskets, I am not sure what Rich is doing I sent a paypal payment to him for what he said he sell them to me for shipped and he hasn't gotten back to either of my emails yet, I am sure he is just busy.

HEAVY_RL

iTrader: (1)

Not to shabby.

LoL, I'm sure he only got one email today

Matt W

Thanks, don't think I want to go through the process of making those flanges again. So cost was $43 for 1x3 sheet metal, $20 for all the cutting oil, $16 for jigsaw blades..I still have plenty of those, 9+15 for the hole saw which is still in great condition.

My friend is letting me use his plasma cutter this coming Tuesday, I am going to get a bunch of rough ones and If I get enough interest to make these in the TL forums I might get my own drill press and try to make a good bunch. I think the price for each flange would be $40 but that is because it takes me 2 hours to just get the holes done.

Also the email was Thursday, but anyway, yes I am sure he gets many emails.

Maintenanceman

Result is much more better than i expected by those first photos
If you use plasma cutter to make those holes it might be hard to drill them to right size because the edges of those holes will be hardened by that heat.
Use it only to cut the shape of that flanges. This might be your plan anyway?

Matt W

I wasn't expecting much after I cut those original shapes but I spent about an hour at the grinding wheel to get the shape right, cutting the bolt holes actually took about 2 minutes for each hole with the drill press..cutting the center hole takes about 30-40 minutes a piece. If I kept doing these I would get the method down pretty good.

Yes I am just cutting the shape of the flanges with the plasma cutter, hopefully I can still grind down the edges even though they will be hardended, the holes will always be cut with the drill press because that is the part that actually matters that it is correct.

Matt W

Lol the RL sounds like a truck without the J pipe connected...here is a video! I am driving it to the muffler shop this way in the morning, my neighbors are going to love me!

https://www.youtube.com/watch?v=Icu3HIN0RuE

HEAVY_RL

iTrader: (1)

it does sound like a truck, because a v6 is a v6... 3.5, 3.7, 4.3 they all sound the same.

thats why I warned you early on to be careful in what you build to get the tone you want.

Dont go to far with an open pipe, cold air on hot valves isnt a good combo

Matt W

Oh no I think it sounds pretty awesome right now, its just way to loud, I think what I picked out will work getting now that I know how it sounds with nothing connected.

But anyways we will know by the end of the week.

EL19

iTrader: (4)

That was me that said to get the gaskets from Honda, I could've sworn I had purchased those from Honda before but that was a while ago.

Parts look great. Have you test fit them?

Matt W

I took the RV6 pipe off and tested the flanges they work as you can see below. Also I sanded them down a little more to give them a more shiny look so these are the final pictures before they went on. I might have the car back tonight but I'm not 100% sure.

Matt W

Exhaust system is done!

vletnguyen

iTrader: (1)

Looks good and a hell of a lot cheaper then ordering jdm exhaust.

However, i see a lot of sharp bends. Did you measure the length of exhaust? Looks like one runner is longer then the other.

Now to the most important question... HOW DOES IT SOUND?

Matt W

Yes one run was slightly longer than the other, my exhaust guys said I really shouldn't have to worry about it because the X-Pipe is there and that will help the most in equalizing the pressure between the two runs.

The guy actually stayed after and worked from 5 to 8 to get my car done. I payed $300 cash for the work and all the pipping they did. All welds are MIG welds but they look very clean, they also sprayed all their welds with grey hi-temp engine spray to prevent rust. I am going to follow up with by putting a hi-temp clear coat on the entire exhaust.

The engine has a deep sound when I start-up and under 2k RPM it is pretty quiet, it was louder than I expected when driving...you can definitely hear it upon acceleration, I don't hear any rasp but I hear something rattling when I am driving and I can't really tell what it is but it doesn't bother me to much.

There is a slight drone while driving and I am thinking I maybe should have gone with the Vibrant Ultra Quiet resonators but its too late to go back now and its not to bad. As time goes on I might swap or add another set of resonators

As far as power goes I feel like the power band is more equalized where as I get more torque and hp available instantly, rather than waiting to hit v-tech with the jpipe, but where I hit vtec with the jpipe I really didn't feel a huge boost when I hit vtec with my new true-dual setup...I wish I could dyno and see the real difference.

253RL

Looks great kudos for sticking it out, if you get tired if it it or want it louder or quieter, swapping either mufflers or resonators will do the trick, congrats and nice work! Now get some flybys!!

Maintenanceman

You can finish them with grinder, they wont get so hard.
Water or laser cutter would be the best choice if someone wants to make lots of these.

HEAVY_RL

iTrader: (1)

nice... now on with the vids.

oo7spy

You selling the J-pipe? If so, I got first dibs.

Matt W

I am selling the J-pipe, it hasn't gone through a winter yet (about 3-4 months old) so looks as good as the day I put it on there besides the obvious discoloration from the heat...but it will look like this after a week of driving.
I am asking $300 including shipping, new nuts and bolts, and new pre-cat gaskets, you will have to get the gasket for the mid section but that is universal and should be pretty cheap (less than $5). A new j-pipe will cost $500 shipped and won't be any different than this one after a week. I will post an ad in the marketplace sometime this weekend.

Anyways onto the exhaust here are some videos, not great videos because wind was blowing and I don't think mic picked up the sound very good...but better than nothing.

HEAVY_RL

iTrader: (1)

The person who helped the most should get dibs.

Matt W

Here are the rest of the exhaust pictures:

Carbon Legend

all i hear is wind in the video's. looks to be a clean exhaust. what color blue is that? don't believe I've ever seen that color.

HEAVY_RL

iTrader: (1)

thats the Opulent Blue Pearl

Matt W

Yep opulent blue pearl...will be getting my bumper replaced next summer. Hoping some idiot driver bumps me this winter and has to pay to replace it.

rockstar143

iTrader: (6)

Great job on the pioneering...
somewhat raspy at certain rpm's but overall, great sound.

Matt W

Thanks, now that I have had it for a few days I think I notice a definite loss in low end torque but I think there are gains when I start reaching higher rpms and speed. I have really know way to know though.

There is also a rattling noise I can hear at like 3k RPMS, I think it is just the whole exhaust being loud and vibrating something..maybe the heatshields, sounds like its coming from the glovebox area. Doesn't bother me too much and I only hear it when the radio is off.