Josh’s S15 PT3: Exhaust

The last item to tackle was Josh’s exhaust as had a modified chopped up exhaust which hung low and he wanted a raspier note. 

Forgot how short Silvia exhausts are after making one for the jzx. 

The resonator was annoyingly a bit larger than the 3” advertised which would’ve resulted in a pretty bad time welding. 

Grabbed a set of pipe expanders to try remediate this. 

After much time spreading I got a much better fit up. Fit up is super important for tig. 

Tacked on and ready to weld. 

From the cat I used a 30 degree long leg mandrel bend with a straight extension then a bit of straight after the resonator. 

Fused together let’s see how it holds up. 

Progress being made. 

Mocking up on the car getting ready to tack it to the flange. I believe I used fencing wire?

Clearance to the chassis rail from the cat

Bullet resonator fitting nicely. Could use an offset slim oval muffler too (in/out same side) which we should’ve since this ended up too loud/raspy down low. 


We also tried an exhaust control valve. Unfortunately I drilled too many holes into the butterfly valve so it doesn’t do a great deal in terms of noise reduction. Hopefully with a bigger muffler it’ll help out if we replace the bullet resonator. 


Mocking up the blast pipes. So shiny

I made a 15 degree pie section to join up to the blast pipe section. 

And welded the vband to the blast pipe section too. I should’ve positioned the section closer to the tip for better clearance as it’s borderline to being the lowest part of the system. 

Pew pew

Tacked and welded the 2 bolt flange too

I made a 5 degree cut onto another piece of straight to straighten it out where it shoots past the sway bar. 

Main section welded up not too far off. 

I believe I added another 5 degree piece to the end of the 15 pie section so it’s a total of 20 degrees here. 

Fused up. 

Then ran out of gas lol. 

Making do with a small garage/workspace. 

Immortalised. 

Back on the car just needed to make hangers next. 

Used some wire to mock up hangers

Upgraded to gktech exhaust hanger bushings. Highly recommend they’re super stiff!

Hangers tacked. Quick bev before welding time. 

This really sucks to do on the ground. 

But it’s all done. 

Made sure the hangers are pulling against each other to keep tension on the exhaust so it doesn’t flop around. 

Timeless