Stainless Works Custom Exhaust - Hootie And The Blowpipes - Tech

Next, I traced a 1-inch border around the tip and shaped my tip flange using a grinder.

I then shaped the flange to flow with the bedside. Because the back of the tip is 21/2 inches and the front is slender, I needed to be sure the opening was big enough to accommodate all parts. Using a hole saw and a cutoff wheel I slowly cut out the opening on the bedside.

Fast forwarding a bit, here is the tip all welded together and installed. I welded two bolts to the backside of the flange and ran them through the bedside to secure the tip.

Creating the tail end of the new exhaust tips was a bit tricky. I used another piece of exhaust tube and shaped one end to match the rear of the tip, but I was sure to leave the other opening the full 21/2-inch OD. The other obstacle was getting the angle right, but again this is just part of doing a DIY exhaust system.

Here's the finished product. Notice the gap at the end. When mounted, there is a 1/2-inch gap between the two. There are several reasons for this. One, the gap won't transfer the heat of the exhaust tube to the bedside. Two, I'm going to wrap the gap in exhaust wrap, which will dampen vibration and keep the exhaust from tearing up the bedside. The exhaust wrap will also seal the gap and reduce heat. As added protection I created a gasket from the wrap to mount between the tip flange and the outer bedside.

The last step is to install these hangers. Stainless Works offers several styles of hangers: vertical, horizontal, sideways, weld-on, clamp-on, etc., that allows you to custom mount the exhaust per your needs. The hangers come with special grommets for a clean install.