Morning guys. Spent yesterday fabricating a new 3" mandrel bent exhaust for the datto. Its my first time making one and i didnt find it as hard as i expected it to be, just time consuming. After fabrication i installed it, put weight on the rear axle and rattled the exhaust to see if it would foul on anything but to my suprise it didnt! :D Over the moon with how it turned out and the sounds is unbelievable! I mean, its not legal for sure but not as loud as the excels you see running round with milo tins on the end of their exhaust.

Here are the pics

ENJOY!

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lol those welds that were originally on the flange were all kinds of quality

probably really should have tried to do small stitch welds rather than just continuous tacks. but yeah looks the goods anyway. is there no muffler in it?

Cat-back? Which 1200 uses a cat?

No, no muffler yet! No one here in my village stocks thin 3" mufflers to suit this car. :( Has a VERY nice note to it though.

The car already has a 3" dump + front pipe in 1. Fromt here it was reduced to effectively a 2" exhaust system.

And yeah i hear you with the welding. Im not the worlds best welder, havent done any in months but i think i did ok, it cleaned up pretty well at the end anyways, but damn do i hate those wire brushes! Hands and stomach were covered in them! lol!

Looks good. Welding looks neat at least. How much for the materials?

The metal cat was the most expensive It was $170. 2 lengths of 1 meter 3" mild steel was $20 each. The 45 degree bend was $25 and the doughnut was $49

To get a custom one made here where i live would have set me back about $600 :(

wow i payed 300 hundred for my whole system and it took the guy at mufflers R us an hour and a half to do including welding on flanges through out

that was 3 sets of flanges with ganskets and stainless bolts
a super cat muffler
new rubber mounts and brackets to support it
and its a 2 and a quarter inch system

what car was your system goin on ?

My one thats up for sale (1200 coupe with a highly modified CA18det). I have a guy that is intensely interested in it for racing over in South Australia. Only thing is he is still thinking about it but in the mean time its still my daily and it needed to be done. It has 4x SARD 650cc injectors ready to go in and my mate over at Gentech in canberra will be doing the tuning and installation. He even insisted on doing a couple of cold starts for free. So hes got the job. :) It gets down to a bout 1-2 degrees where i live in the mornings, sometimes below 0 and canberra is very similar so i do appreciate it.

It took me bout half hr to pull the old system off and all in all took me about 4 hrs to fabricate and install. Though i tihnk im a lot more fortunate thatn most because i have access to a lathe, a 20" bandsaw, a few different sized angle grinders, bench grinder and a few polishers plus a decent 3-phase MIG welder (CIG) and plenty of space in the shed. I suppose thats one good thing about being on a farm... But would anyone want my $2200 quaterly power bill? :P

**Mind you the metal cat i got is of the VENOM brand from the US of A. Its euro 3 compliant but i highly doubt its ADR approved hence the price of the uniy, but im not complaining. :)

The last guy who did that exhaust had to be the worlds worst welder... I had to grind and file out all the messy welds, machine the flange back to being flat. From there i just tacked the cat on, then a straight section (roughly measured from the old system) tacked the angle on, another straight section,then a 45 degree bend (i cut the doughnut in half and then cut one of the halfs in 4x lots of 45 angles), another straight unit, then 2 more 45 degrees, a short straight, the last 45 angle and then mounted to floor and out the back.

The entire exhaust still uses the factory mounts, the rubbers were in exceptional nick and reused them. I even managed to pick it up so its not so low aswell. The most time consuming was filing the dags burrs of all the joins and then making the edges all flat and even for the bends. I want it neat and tidy even though its most likely going to get ripped off by the hopefully new owner. But... if u do something, you may as well do it right the first time :)

Why do you want a catalytic convertor in your 1200?

Because the engine is a CA18.

In NSW anyways you are required to have a cat converter on any car after 1982 i think it is. But if the engine is newer than the car and the year of the engine is after 82 than you are required to have one.

If i had an a12,14,15 in the car it owuldnt have mattered. Its australia... it sucks otherwise my exhaust woulda been even cheaper! :D