First 3" SS custom downpipe ready !!

[Pisobiker]

I finally finished first one. I was planning to make Rafael's 70mm one first, but had to wait for one more 70mm SS bend to come, so in the meanwhile I made the 3" one.

Result is pretty good, in my opinion. Of course I'm not a pro-welder, so the welds are not the best looking around (don't have a TIG welder), but I belive they are strong and long lasting.

Well.... even if I know there are some guys here who could have made some better looking welds, I'm pretty proud of my job .....
All the junctions are carefully matched and WG duct merging carefully cut and smoothed out, without lips or steps anywhere.
The pipe matches RS2 specs downpipe with same clearances.

I have to admit it took considerably more effort to make it than I would have thought at first, expecially because of some complex parts such as the initial cone, WG duct merging, and the Lambda probe plug.
For the latter one I couldn't find any suitable threaded plug so I had to make them myself from a tubular piece of SS.
I definitly wouldn't have liked to just weld an iron nut on the pipe


Here are some pics. Now I definitly need to spend some time with my family.

will be back tomorrow in the afternoon.

Ciao


Marco

[Pisobiker]

another one:

[Pisobiker]

and another:

[Pisobiker]

a comparison pic with RS2 70mm downpipe:

[Pisobiker]

last one:

[Greg_S]

Looks excellent, when can i get one....?

[Corey]

Nice!!!
I really must get round to making the tubular manifold for the ur...

[Dutch_RsBlueS2]

Nice work piso thumbs up

But how did you weld it? Mig/Mag? it doesnt look like a tigged peace.

Cheers Cees

[The Spanish]

Great job Marco,

Welds look so much better than the original downpipe.

Can't wait to have mine

Cheers,

Rafael

[SteveH]

Nice work Marco!

If you make enough to sell, I'll buy one

[Stick Insect]

Dutch_RsBlueS2,

It looks like Mig, from the photos, he seems to have used stainless wire as well. It has been a lot of work for him I can tell.

Being stainless it will last longer than an Alfa Sud!

The downpipe looks to be a lot better flowing than the original RS2. downpipe.

David

[Pisobiker]

Thanks for the appreciation guys.
I used an inverter type electrode welder with SS electrodes (not TIG).


Apart from the care put in matching all the junctions togheter (to have smoothest internal surfaces as possible) I also took some time to smooth out internal merging of WG pipe to main pipe, which now doesn't have rough internal welds, metal lips and steps like the OEM does (I was surprised on how badly the original one is).

The conical section is also an improvement (complex to make) even to my actual downpipe (the one I built when upgraded to RS2 specs, a while back).

I have the flanges to make other 8 pieces, at the moment, so if someone is interested I think I could build some others (I think I'll not be able to manage making more than one every 10-15 days, though). Even if it took considerably more time to make one as I was thinking at first, I will keep my word and offer them at 220 euros each + shipping. Considering the time and complexity of the job I think this is really a good price that only charges for material costs + a very low cost-per-hour for my time.

The above price will also include my medical expenses ......
I almost cut my right hand forefinger togheter with a pipe, yesterday ... ouch it hurts !

.... I can't understand why I always need to get injured when doing mechanical jobs !


Positive note is I'm getting a nice "golden tan" over my face thanks to the welding machine


Marco

[Pisobiker]

P.S.

Rafael, yours is next


Marco

[Stick Insect]

Marco,

Nice job, I am impressed especially finding out you have arc (stick or MMA)welded it. I consider myself a good welder and you have done a great job with the stick. I feel that Tig would be easier but as you say, you should suffer for your art.

I feel that there will be a big waiting list for your work...... Is it one finger per manifold?

It's Ok I don't need one, my 7A engine wouldn't know what to do with it!

D.

[Pisobiker]

Rafael's 70mm downpipe is ready.
finished about half an our ago.

Here are a couple of pictures compared to the 76.1mm one (3").


Marco