3rd Gen. True Dual Exhaust Build

Skydvrr · Nov 13, 2020

rj_taco[OP] said: ↑

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.

Thank you!
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Thanks buddy. I'll totally look into his YT. You inspired me, imma order all that shit from Amazon soon

Skydvrr · Nov 13, 2020

Phich said: ↑

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
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there are some truly talented welders out there.

Trident904 · Nov 13, 2020

@rj_taco, nice work sir. If you don't mind me asking, what was your cost to build?

CrazyAirborne · Nov 13, 2020

Trident904 said: ↑

@rj_taco, nice work sir. If you don't mind me asking, what was your cost to build?
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He mentioned it further back, "a bit over 1300" in steel.

Trident904 · Nov 13, 2020

CrazyAirborne said: ↑

He mentioned it further back, "a bit over 1300" in steel.
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Ahh, okay, I must have missed that.

kgilly · 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.
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very nice job....

CrazyAirborne · Nov 13, 2020

this build is incredible! great work dude!

crashdb · Nov 13, 2020

Holy crap! Welds are beautiful! And I gave up on decent sounding exhaust for this truck, but your creation sounds perfect.

rj_taco · Nov 13, 2020

Phich said: ↑

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
Click to expand...

Thanks man. The reality is, some turn out great and some not so much. I had to make myself quit trying to make it look perfect and focus on what’s important.

spectacolar.adventures said: ↑

Looking great! that's a lot of pie cuts!
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Thanks! Yeah, got a bit carried away.

Skydvrr said: ↑

Thanks buddy. I'll totally look into his YT. You inspired me, imma order all that shit from Amazon soon
Click to expand...

You should totally do it. I Didn’t even raise the truck for all of it. One of the learning curves for me was how much stainless shrinks when welded. Lots of tack to hold in place. Another crazy thing, the full exhaust length expands when hot. Like almost 1/2”. When it cools it shrinks back! Crazy.

Check out KaneKid Welds YouTube, insane skills. Learned a ton from his videos. HourGlassIngenuity is another one.

Skydvrr · Nov 13, 2020

rj_taco[OP] said: ↑

Thanks man. The reality is, some turn out great and some not so much. I had to make myself quit trying to make it look perfect and focus on what’s important.

Thanks! Yeah, got a bit carried away.

You should totally do it. I Didn’t even raise the truck for all of it. One of the learning curves for me was how much stainless shrinks when welded. Lots of tack to hold in place. Another crazy thing, the full exhaust length expands when hot. Like almost 1/2”. When it cools it shrinks back! Crazy.

Check out KaneKid Welds YouTube, insane skills. Learned a ton from his videos. HourGlassIngenuity is another one.
Click to expand...

I'm probably not gonna go duals but just use the URD y pipe into one with a single resonator and the borla with side exit in front of the rear. Think it'll need two resonators?

Thanks for the YouTube recommendations. I chew through ~40 gigs of data a month at work, mostly YT. Excited for some new shit!

Xx_Evilvirus_xX · Nov 13, 2020

WOW JUST WOW OP

BRAVO

rj_taco · Nov 13, 2020

kgilly said: ↑

very nice job....
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Thanks!!

CrazyAirborne said: ↑

this build is incredible! great work dude!
Click to expand...

Thank you!

crashdb said: ↑

Holy crap! Welds are beautiful! And I gave up on decent sounding exhaust for this truck, but your creation sounds perfect.
Click to expand...

I think the secret is an equal length y pipe. Unequal length just muds up everything before they converge to a single pipe. Some ppl like the sound, I wanted to eliminate it.

Xx_Evilvirus_xX said: ↑

WOW JUST WOW OP

BRAVO
Click to expand...

Thank you!

rj_taco · Nov 13, 2020

Skydvrr said: ↑

I'm probably not gonna go duals but just use the URD y pipe into one with a single resonator and the borla with side exit in front of the rear. Think it'll need two resonators?

Thanks for the YouTube recommendations. I chew through ~40 gigs of data a month at work, mostly YT. Excited for some new shit!
Click to expand...

It depends on how aggressive you want it to sound. A single resonator and a large muffler will tame most of it but will still have a resonate frequency in the 2-3k range. Mine has developed one in that range, so I’m making a spiral insert to see if I can eliminate it. It’s not bad, just trying to make it sound uniform throughout the RPM range.

Roostfactor · Nov 13, 2020

rj_taco[OP] said: ↑

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!
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Good stuff.

While I enjoy it alot, most people have no idea how much time and $$$ just in materials cost.

Skydvrr · Nov 13, 2020

rj_taco[OP] said: ↑

It depends on how aggressive you want it to sound. A single resonator and a large muffler will tame most of it but will still have a resonate frequency in the 2-3k range. Mine has developed one in that range, so I’m making a spiral insert to see if I can eliminate it. It’s not bad, just trying to make it sound uniform throughout the RPM range.
Click to expand...

I guess I better get two haha. Thanks for the beta!

rj_taco · Nov 13, 2020

Roostfactor said: ↑

Good stuff.

While I enjoy it alot, most people have no idea how much time and $$$ just in materials cost.
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No kidding! It’s expensive. Although I did a lot of welding, argon alone was over $200. No reason a similar exhaust system, just the middle section, for a Ford raptor goes for 3k!

Skydvrr said: ↑

I guess I better get two haha. Thanks for the beta!
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I would put one on each side like I did. Really takes care of the rasp.

CdnSldr · Nov 16, 2020

Damn that sound is smooth.

Anyone aware of an “off the shelf” exhaust system that sounds that good?

trd pr0 · Dec 5, 2020

Like to put an order in

rj_taco · Dec 6, 2020

CdnSldr said: ↑

Damn that sound is smooth.

Anyone aware of an “off the shelf” exhaust system that sounds that good?
Click to expand...

I’m not aware of one that is built similar. The newer URD spec u with a resonator may come close.

trd pr0 said: ↑

Like to put an order in
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I wish I had the time to build more. I’ve been toying with the idea to build an equal length tuned y-pipe, not anytime soon though.

trd pr0 · Dec 8, 2020

https://cdn.shopify.com/s/files/1/0013/4342/2512/products/Tacoma-Tucker_1296x.jpg?v=1594140778
Do borla make a similar exhaust exit like stromung

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