SWB Quattro Project

[Bram]

Sorry, I can't keep up with all the Audi forums

[Topolini]

"Hand made" ?

[G60Rallye]

I have been spending ages on the exhaust recently. Its turned into the most difficult thing I have ever made due to the oval tubing. I got a tool made up by Nortech to push into the oval tubing to make it round again for the transitions between the 2. This failed as the oval has more metal in it to get the same surface area as the round. This is due to a circle being the most efficent use of space.

The tool:





So there was only one option left and that was to make the transitions myself. I ended up splitting the oval and crushing one end in the vice then opening the end out to meet up with the circle. Then piecing in 2 fillets to complete them. The downpipe also has an oval bend which goes under the driveshaft which I made by splitting a 2.5" bend and widening it.

So here is the result of many hours of cutting, tweeking, and tacking it together.





Not much clearance to anything realy but that was always going to be the case with the 3.5" tubing.









Very pleased with how the downpipe has turned out after all the work. The rest of it will be far easier as there isn't anything to avoid now!

[terrybullwon]

Nice one Hamish.

Its a sod working with such large bore tube!

[Bram]

oval tubing sounds interesting. I still presume it has influence on the flow, because the flow is somewhat altered

Any insights on this?

[Le S2 Audi]

Dumb Question - and please remember that I am no mechanic!!!

But is the downpipe not too close to the driveshaft boot?? Will the heat not affect the rubber?

Awsome build thooo...

[Jonnybravo]

Love this car !

As for oval tubing, a few works cars run oval exhaust systems so they can't be that bad.

[Bram]

Love this car !

As for oval tubing, a few works cars run oval exhaust systems so they can't be that bad.

Check

[G60Rallye]

I dont think the oval will have any effect on the flow. The transitions are nice and smooth and the oval has the same cross sectional area as the round.

The pipe is far too close to the c.v boot to run it without any heat proofing yes, but I wanted it as high off ground as possible for ground clearance.

[Le S2 Audi]

I dont think the oval will have any effect on the flow. The transitions are nice and smooth and the oval has the same cross sectional area as the round.

The pipe is far too close to the c.v boot to run it without any heat proofing yes, but I wanted it as high off ground as possible for ground clearance.

That answers my dumb question... Thanks Hamish...

Awsome thread....

[Thuppu]

Amazing project and stunning skils! This kind of projects is just awesome and gives the feeling your own projects is so tiny and childish...

Some Thermotec wrap on the dp should do the job and protect the cv.

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OMG....Keep like this........ Holy ****!!!!!!!!

[G60Rallye]

Had a day on it today and got the centre section of the exhaust almost finished.



Another transition:



Split a 2.5" bend and opened it out to make an oval bend:



Some crap pictures of it on the car. It sits higher than the floor which is exactly what I was after with the oval tubing:

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!!!!!!!!!!!!

[Error404]

awesome! I could do with your skills on mine Hamish, managed to tear a great chunk out of my resonator pipe and shear off my CV heat shield in the process yesterday morning, didn't even make it off my lumpy driveway