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Discussion Starter · #1 · (Edited)
My catalytic converters need to be replaced and I don't like the stock exhaust system, so I'll be fabricating a new one while the truck is down for an engine swap.
I'm on a budget but I also don't want garbage like press bent tubing or mild steel that will rust off in a year. Because of cost, I'm forced to use cheap Chinese stainless for some of the components (don't hate, there's Merican in here too).

Here's what I've collected and plan to get so far.
350Z headers- Hoping they fit. For $80 they are worth a shot.


Ø2.25" tubing for the dual sections- Dual sections will be equal length in an effort to "smooth" the exhaust sound.

Dual Emusa Ø4" x 10.5" long mufflers- Straight through design with fiberglass packing.



Dual Thunderbolt 400CPI "high flow" spun cats- Might not pass an emissions test with only 2 of these, but I don't have to worry about testing in WI.



Dual Ø2.25" Flex-pipes



Magnaflow Dual Ø2.25" to single Ø2.5" y-pipe w/ Ø2.5" to Ø3" cone- The idea is to create a venturi effect by necking the single section down momentarily and then gradually increasing it.




Single Ø3" tubing- Let it flow!

Single Jones Maxflow 5"x8" oval x 18" long muffler. Straight through design with fiberglass packing. This muffler along with the single 3" tubing should produce a nice deep sound without being too loud.




V-bands- All flanges will be cut off and replaced with v-bands.
 

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your 350z headers got me thinking as anyone tried adapting a g35/350z aftermarket cat back to the truck? i like the way those vq's sound with exhaust set ups
 

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Interested in how this goes as well, my mechanic specializes in Gs &Zs, so I'm anxious to see how this works out and sounds...
 

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...very interested to see and hear your progress!
 

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Discussion Starter · #5 · (Edited)
Found out that DNA Motoring makes long tube headers for the VQ40 and they are cheap so I bought them.
I'll still test fit the 350Z headers because I'm curious, but I won't be using them anymore.
These long tubes have pretty large diameter collectors (Ø2.36" ID) so I'm thinking about adding venturis here too that neck down to Ø2".

 

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How is the quality on those headers? For only $150 I could assume they aren't that great. I could be wrong, but I would be very very skeptical.
But, please, prove me wrong so that I could ever justify trying them out one day

Sent from my XT1585 using Tapatalk
 

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Discussion Starter · #9 ·
The headers honestly aren't that bad. Only part I really have a problem with are the collectors, the insides could really use some grinding (typical of Chinese headers). The outlet diameter is also huge, but that's how most headers are.
I would love to have Doug Thorleys instead, but there's no way I'm spending that kind of money when these are so cheap.
 

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The headers honestly aren't that bad. Only part I really have a problem with are the collectors, the insides could really use some grinding (typical of Chinese headers). The outlet diameter is also huge, but that's how most headers are.
I would love to have Doug Thorleys instead, but there's no way I'm spending that kind of money when these are so cheap.
Could you take some photos of the inside collector, flange, and some of the welding?

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Surprisingly that doesn't look too bad at all.

I'm gonna stay subscribed for the finish install. I'd like to know how well these mount up.

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Thinking the same thing, not bad looking at all::smile::
 

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Thinking the same thing, not bad looking at all::
I would prefer them to have a short tube style. Long tubes have a real bad tendency to throw codes after Install for o2 inefficiency, unless you uprev tune. I need to talk to someone on his install to see how he keeps his long tubes from throwing codes on his Xterra.

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Discussion Starter · #18 · (Edited)
Mocked up the headers before installing the engine to make sure they cleared the block.


Used axle straps around the factory manifolds to remove and install the engines. Worked great along with the load leveler.


Video of it running with open headers. It was idling around 2k and was very loud. I'm surprised my phones microphone could handle it this well.
https://youtu.be/o73BxlVHkew

Now that I know it runs, I can start fabricating the exhaust.
 

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Discussion Starter · #20 · (Edited)
Made some progress today. Was planning on doing more, but I ran out of argon.


Made the header venturis.


I'm teaching myself how to TIG, so don't expect weld porn.


I plan on cutting more off before the venturis.




Ran out of gas while welding the Y-pipe reducer, so progress came to a halt.


Have also been designing and 3D printing fabrication tools.




 
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