3rd Gen. True Dual Exhaust Build

rj_taco · Sep 23, 2020

cubie said: ↑

In this picture, what is that connection between both sides for? The section just in front of the actual muffler, where you welded both pipes together with some kind of dump pipe.
Click to expand...

It’s vacuum actuated exhaust cutout (butterfly valve) that will open with a switch (or ECT on as an example or triggered by a boost controller at xx psi). It will bypass the Borla muffler, overkill for a NA setup but will come alive when boosted. That’s the idea at least.

Kaptain_02 · Sep 23, 2020

Excellent fab work, that is a work of art.

Keep doing stuff like this, it’s cool and you’ve got the skills

rj_taco · Sep 24, 2020

Kaptain_02 said: ↑

Excellent fab work, that is a work of art.

Keep doing stuff like this, it’s cool and you’ve got the skills
Click to expand...

Thanks! I’ve been tig welding a total chaos spindle gusset up, funny when you catch yourself stacking dimes on something nobody will see!

outlaw.taco · Sep 25, 2020

rj_taco[OP] said: ↑

Thanks! I’ve been tig welding a total chaos spindle gusset up, funny when you catch yourself stacking dimes on something nobody will see!
Click to expand...

What welder are you using, let’s see them if you don’t mind sharing

Stocklocker · Sep 25, 2020

rj_taco[OP] initial post: ↑

Just wanted to share my exhaust build in its own thread vs posting updates on the Ov TT thread.

Reason why I decided to do this was to get rid of the stock exhaust in preparation for the twin turbo kit (PowerMax, full fuel upgrades) to improve flow and sound and learn something new. In my opinion the stock exhaust has several limitations, from inadequate pipe IDs and bends, to unequal y pipe lengths (for sound).

I decided on a dual 2-1/2” exhaust after reading and watching videos on different V6 twin turbo setups. The original plan was a divorced system, but settled on a X pipe design to incorporate a cutout. In the end my goal was to have a flow through system that was quiet when needed, no drone, no rasp, no pops/bangs and made to last.

Parts (all 304 SS):

2 bolt flange: Amazon, 2.5” Stainless Bros 603-06320-0000
Gasket: Amazon, HYCC 2-Bolt 2.5''
Exhaust pipe: Amazon, Squirrelly 2.5" universal kit 16 ga - SPP FABKIT-5
Resonator: Amazon,Vibrant Ultra Quiet - 1141
Muffler: Amazon, Borla ProXS - 400286
Cutout: Amazon, Keenso 3” vacuum activated, normally closed - Keensogbwoqer15z-02
O2 bung: eBay, fab-pro notched
V-bands: eBay, Yonaka YMVBFC25
Over axle mandrel bend: eBay, PLM U L J (didn’t use most of it, would not do this again).
2.5 to 3” transition: eBay, fab-pros
3” pipe for cutout turndown: eBay, khaos-Motorsports 90 short
Exhaust tips: eBay, catinbow 2.5” to 3” double walk angled (cut off)
Hangers: eBay, Yonaka 1/2”x9.5”

Welder and parts: Amico TIG-225 that I modded for pre/post flow control, variable pulse, tack mode and foot pedal. CK worldwide 17 torch, Furick FUPA #12, .045/1/16” 308L filler, 3/32 blue electrode.

Weld settings: 100% back purged @ 5-10 cfh, torch mostly at 20-25 cfh. Pipe to pipe with bad fit up, 55 amps (w/foot pedal) .045 filler. Pipe to pipe with good fit, 1.5 pps, 25% peak, 55 amp peak, 10% background amps, autogenous (no filler). Flanges were done mostly with the same pulse settings @ higher amperages with 1/16 filler.

Band saw: Amazon, 4”x6” WEN 3970 T w/ starrett blade

I had no previous experience doing this, just watched videos (kudos to Jody, weldingtipsandtricks YouTube channel) and learned as I went. I took time to practice and hoped for the best both in fabbing and what it would sound like.

A few pictures, feel free to ask any questions. I will do my best to answer.

Started with X pipe, from 2 U-bends cut at 30% ID and 45 degrees:

Then added a 90 using pie cuts (9+9 degree, short radius).

Fabbed left and right sides, which replaced the secondary cats with vibrant resonators. Left side is a 55 degree offset of center, right side is 45 degrees.

Added v band flanges to X pipe and welded it up:

3” cutout parts (pie cuts 9+9 degree):

All fitted and checked for clearance:

Welded O2 bungs and finished welding both sides:

Placed the Borla muffler as high as I could:

Added hangers (stock locations):

On to the most challenging piece! Took 41 pie cuts and lots of time. I wanted to be able to fit a 33” spare (move bracket) and allow full droop (RXT + ext. length FOX 2.5), I still want to fab a turn down that can be swapped when needed. I’m changing the hangers to BAMF as well.

Onto the exit, I wanted the tips to be as high as possible for looks with enough clearance. I had to move the hanger further up as well.

Here is the sound clip of a warm start, revs to 4-6k. Ov 2.0 tune. No other mods, stock air box. Overall I’m very pleased with the tone and volume, no rasp what so ever, no drone and quiet when needed. My calibrated butt dyno (not) tells me there is a perfomance improvement. The truck feels more lively on low RPM for sure, more noticeable up top, which is surprising given the pipe diameter.

https://vimeo.com/459999807

I still need to hook up the cutout, which will give the tone a bit more of an attitude. The truck is back in the basement for other mods prior to the twin turbo install, which hopefully will happen by mid October. I’m expecting the exhaust tone to change a bit with TT’s (catted down pipes) and be a bit quieter because of the turbos. I’ll update as the install moves along.
Click to expand...

Bravo. That looks amazing. One of my favourite things about being in the Tacoma club is getting to see all the talent and ingenuity on display here. Gives me hope for the future of humanity.

Well done.

rj_taco · Sep 25, 2020

outlaw.taco said: ↑

What welder are you using, let’s see them if you don’t mind sharing
Click to expand...

I’m using an Amico TIG-225, I added a foot pedal to it though.

Still working on it, got one side almost done. Taking my time to let it cool.

twitchhero · Sep 25, 2020

This is one of the cleanest exhaust systems ever built for a Tacoma. Great job!

Fleischwagen · Sep 26, 2020

Whoaaaa. Incredible job!

rlx02 · Oct 19, 2020

rj_taco[OP] said: ↑

I did record this, sounds better with headphones.

https://vimeo.com/461194737
Click to expand...

Great work! Almost sounds like a VR38 at WOT.

rj_taco · Oct 19, 2020

rlx02 said: ↑

Great work! Almost sounds like a VR38 at WOT.
Click to expand...

Thanks! It doesn’t sound like a truck, sounds more like an import with a tuned exhaust. Should sound even better with the twin turbos spooling in the background!

Chris(NJ) · Nov 12, 2020

Nice work!

Roostfactor · Nov 12, 2020

rj_taco[OP] initial post: ↑

Just wanted to share my exhaust build in its own thread vs posting updates on the Ov TT thread.

Reason why I decided to do this was to get rid of the stock exhaust in preparation for the twin turbo kit (PowerMax, full fuel upgrades) to improve flow and sound and learn something new. In my opinion the stock exhaust has several limitations, from inadequate pipe IDs and bends, to unequal y pipe lengths (for sound).

I decided on a dual 2-1/2” exhaust after reading and watching videos on different V6 twin turbo setups. The original plan was a divorced system, but settled on a X pipe design to incorporate a cutout. In the end my goal was to have a flow through system that was quiet when needed, no drone, no rasp, no pops/bangs and made to last.

Parts (all 304 SS):

2 bolt flange: Amazon, 2.5” Stainless Bros 603-06320-0000
Gasket: Amazon, HYCC 2-Bolt 2.5''
Exhaust pipe: Amazon, Squirrelly 2.5" universal kit 16 ga - SPP FABKIT-5
Resonator: Amazon,Vibrant Ultra Quiet - 1141
Muffler: Amazon, Borla ProXS - 400286
Cutout: Amazon, Keenso 3” vacuum activated, normally closed - Keensogbwoqer15z-02
O2 bung: eBay, fab-pro notched
V-bands: eBay, Yonaka YMVBFC25
Over axle mandrel bend: eBay, PLM U L J (didn’t use most of it, would not do this again).
2.5 to 3” transition: eBay, fab-pros
3” pipe for cutout turndown: eBay, khaos-Motorsports 90 short
Exhaust tips: eBay, catinbow 2.5” to 3” double walk angled (cut off)
Hangers: eBay, Yonaka 1/2”x9.5”

Welder and parts: Amico TIG-225 that I modded for pre/post flow control, variable pulse, tack mode and foot pedal. CK worldwide 17 torch, Furick FUPA #12, .045/1/16” 308L filler, 3/32 blue electrode.

Weld settings: 100% back purged @ 5-10 cfh, torch mostly at 20-25 cfh. Pipe to pipe with bad fit up, 55 amps (w/foot pedal) .045 filler. Pipe to pipe with good fit, 1.5 pps, 25% peak, 55 amp peak, 10% background amps, autogenous (no filler). Flanges were done mostly with the same pulse settings @ higher amperages with 1/16 filler.

Band saw: Amazon, 4”x6” WEN 3970 T w/ starrett blade

I had no previous experience doing this, just watched videos (kudos to Jody, weldingtipsandtricks YouTube channel) and learned as I went. I took time to practice and hoped for the best both in fabbing and what it would sound like.

A few pictures, feel free to ask any questions. I will do my best to answer.

Started with X pipe, from 2 U-bends cut at 30% ID and 45 degrees:

Then added a 90 using pie cuts (9+9 degree, short radius).

Fabbed left and right sides, which replaced the secondary cats with vibrant resonators. Left side is a 55 degree offset of center, right side is 45 degrees.

Added v band flanges to X pipe and welded it up:

3” cutout parts (pie cuts 9+9 degree):

All fitted and checked for clearance:

Welded O2 bungs and finished welding both sides:

Placed the Borla muffler as high as I could:

Added hangers (stock locations):

On to the most challenging piece! Took 41 pie cuts and lots of time. I wanted to be able to fit a 33” spare (move bracket) and allow full droop (RXT + ext. length FOX 2.5), I still want to fab a turn down that can be swapped when needed. I’m changing the hangers to BAMF as well.

Onto the exit, I wanted the tips to be as high as possible for looks with enough clearance. I had to move the hanger further up as well.

Here is the sound clip of a warm start, revs to 4-6k. Ov 2.0 tune. No other mods, stock air box. Overall I’m very pleased with the tone and volume, no rasp what so ever, no drone and quiet when needed. My calibrated butt dyno (not) tells me there is a perfomance improvement. The truck feels more lively on low RPM for sure, more noticeable up top, which is surprising given the pipe diameter.

https://vimeo.com/459999807

I still need to hook up the cutout, which will give the tone a bit more of an attitude. The truck is back in the basement for other mods prior to the twin turbo install, which hopefully will happen by mid October. I’m expecting the exhaust tone to change a bit with TT’s (catted down pipes) and be a bit quieter because of the turbos. I’ll update as the install moves along.
Click to expand...

Blown away man, well done!!!

rj_taco · Nov 12, 2020

Chris(NJ) said: ↑

Nice work!
Click to expand...

Thank you!

Roostfactor said: ↑

Blown away man, well done!!!
Click to expand...

Thank you for sharing your y-pipe build. That’s where it all started for me!!

Roostfactor · Nov 12, 2020

rj_taco[OP] said: ↑

Thank you!

Thank you for sharing your y-pipe build. That’s where it all started for me!!
Click to expand...

You're very welcome! Plenty of room for fabricators here.

Total cost of materials and how long did it take to fab? (If you dont mind sharing)

rj_taco · Nov 12, 2020

Roostfactor said: ↑

You're very welcome! Plenty of room for fabricators here.

Total cost of materials and how long did it take to fab? (If you dont mind sharing)
Click to expand...

Not at all. Material was a bit over $1300. Doesn’t include consumables for welding, argon, etc. Took 1 month to do all of it, off and on. Takes a long time (as you know very well) to cut, fit, prep, tack, weld, repeat!

Skydvrr · Nov 13, 2020

How'd u calculate your pie cuts?

BlkTaco47 · Nov 13, 2020

rj_taco[OP] initial post: ↑

Just wanted to share my exhaust build in its own thread vs posting updates on the Ov TT thread.

Reason why I decided to do this was to get rid of the stock exhaust in preparation for the twin turbo kit (PowerMax, full fuel upgrades) to improve flow and sound and learn something new. In my opinion the stock exhaust has several limitations, from inadequate pipe IDs and bends, to unequal y pipe lengths (for sound).

I decided on a dual 2-1/2” exhaust after reading and watching videos on different V6 twin turbo setups. The original plan was a divorced system, but settled on a X pipe design to incorporate a cutout. In the end my goal was to have a flow through system that was quiet when needed, no drone, no rasp, no pops/bangs and made to last.

Parts (all 304 SS):

2 bolt flange: Amazon, 2.5” Stainless Bros 603-06320-0000
Gasket: Amazon, HYCC 2-Bolt 2.5''
Exhaust pipe: Amazon, Squirrelly 2.5" universal kit 16 ga - SPP FABKIT-5
Resonator: Amazon,Vibrant Ultra Quiet - 1141
Muffler: Amazon, Borla ProXS - 400286
Cutout: Amazon, Keenso 3” vacuum activated, normally closed - Keensogbwoqer15z-02
O2 bung: eBay, fab-pro notched
V-bands: eBay, Yonaka YMVBFC25
Over axle mandrel bend: eBay, PLM U L J (didn’t use most of it, would not do this again).
2.5 to 3” transition: eBay, fab-pros
3” pipe for cutout turndown: eBay, khaos-Motorsports 90 short
Exhaust tips: eBay, catinbow 2.5” to 3” double walk angled (cut off)
Hangers: eBay, Yonaka 1/2”x9.5”

Welder and parts: Amico TIG-225 that I modded for pre/post flow control, variable pulse, tack mode and foot pedal. CK worldwide 17 torch, Furick FUPA #12, .045/1/16” 308L filler, 3/32 blue electrode.

Weld settings: 100% back purged @ 5-10 cfh, torch mostly at 20-25 cfh. Pipe to pipe with bad fit up, 55 amps (w/foot pedal) .045 filler. Pipe to pipe with good fit, 1.5 pps, 25% peak, 55 amp peak, 10% background amps, autogenous (no filler). Flanges were done mostly with the same pulse settings @ higher amperages with 1/16 filler.

Band saw: Amazon, 4”x6” WEN 3970 T w/ starrett blade

I had no previous experience doing this, just watched videos (kudos to Jody, weldingtipsandtricks YouTube channel) and learned as I went. I took time to practice and hoped for the best both in fabbing and what it would sound like.

A few pictures, feel free to ask any questions. I will do my best to answer.

Started with X pipe, from 2 U-bends cut at 30% ID and 45 degrees:

Then added a 90 using pie cuts (9+9 degree, short radius).

Fabbed left and right sides, which replaced the secondary cats with vibrant resonators. Left side is a 55 degree offset of center, right side is 45 degrees.

Added v band flanges to X pipe and welded it up:

3” cutout parts (pie cuts 9+9 degree):

All fitted and checked for clearance:

Welded O2 bungs and finished welding both sides:

Placed the Borla muffler as high as I could:

Added hangers (stock locations):

On to the most challenging piece! Took 41 pie cuts and lots of time. I wanted to be able to fit a 33” spare (move bracket) and allow full droop (RXT + ext. length FOX 2.5), I still want to fab a turn down that can be swapped when needed. I’m changing the hangers to BAMF as well.

Onto the exit, I wanted the tips to be as high as possible for looks with enough clearance. I had to move the hanger further up as well.

Here is the sound clip of a warm start, revs to 4-6k. Ov 2.0 tune. No other mods, stock air box. Overall I’m very pleased with the tone and volume, no rasp what so ever, no drone and quiet when needed. My calibrated butt dyno (not) tells me there is a perfomance improvement. The truck feels more lively on low RPM for sure, more noticeable up top, which is surprising given the pipe diameter.

https://vimeo.com/459999807

I still need to hook up the cutout, which will give the tone a bit more of an attitude. The truck is back in the basement for other mods prior to the twin turbo install, which hopefully will happen by mid October. I’m expecting the exhaust tone to change a bit with TT’s (catted down pipes) and be a bit quieter because of the turbos. I’ll update as the install moves along.
Click to expand...

outstanding work man!

rj_taco · Nov 13, 2020

Skydvrr said: ↑

How'd u calculate your pie cuts?
Click to expand...

The short side on each pie cut dictate the sweep radius. Most of mine are under 1/4” for a short angle/sweep. The more pie cuts the smoother the transition. I used 5 for a 90 transition, so that’s 9+9 degree each. It gets more interesting on off angles and offsets. Just cut a bunch of them and they turn into legos! Check out The Fabrication Series YouTube channel, Justin has a few videos on pie cuts. That’s where I learned the details on how to make them.

BlkTaco47 said: ↑

outstanding work man!

Click to expand...

Thank you!

Phich · Nov 13, 2020

Stellar fab work man! Very impressive, not only for a home DIY - this is better than most pro shops. When you've got form AND function with a weld. I have welded, but am by no means a welder. You sir, can stack dimes as evidenced in this photo:

That is likely the singular best weld I have ever seen. Robotic precision. It's like weld porn.

Flattery session ended

Blueberry.Taco · Nov 13, 2020

Looking great! that's a lot of pie cuts!

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3rd Gen. True Dual Exhaust Build

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