JFR Equal Length Y-Pipe for 2nd Gen Tacoma, T4R, & FJ Cruisers

Whatcha got?

 

I will try to update today guys.

 

Something you showed me when I was there. I want one.

 

Ok all, here is a quick update. It may be jumbled together because I am doing it quickly but it will give you an idea of what I have been doing.

I have noticed my exhaust getting a bit louder as it gets time on it and also there is a drone between 1200-1400 rpm, and again at around 2400. Its not bad but its noticeable. What I am going to TRY to test is various exhaust configurations to cater to what people want and eliminate the drone. Not that I would necessarily build an entire exhaust but at least y'all would have a better idea of what sound you like and the BIG thing is....what sounds AMAZING and LASTS!!!
@loginfailed and @5thGearPinned have either changed their rear exhaust or added mufflers/resonators IN ADDITION TO the Vibrant res and Magnaflow 12579 muffler which is what URD uses in I believe all of their exhaust systems.

Here is @loginfailed's Magnaflow muffler after around 15,000 miles.



This is the inside of the Maggy muffler. Not bad but it is a cheaper stamped design. There was steel wool wrap that I removed. It wasn't rusted at all so it was most likely stainless.

More to come shortly,

Roost

 

After @loginfailed changed out his 3" exhaust for a TRD 2.5" exhaust with cat and Vibrant muffler he wanted to try something different so we installed two 2.25" cats prior to the merge.

This required v-bands and modification to the aft portion of his existing y-pipe. I am not planning on this being an option in the future. It is a one time deal. Maybe @loginfailed could provide a review of performance difference between his various exhausts.

 

How did you get the outlets of the cats to offset and taper inward to the merge like that?

 

Purchased as such. They are in Loginfailed's build thread.

 

So I have contacted a few muffler companies to see if they would comp me some components that I could test and provide that data back here. I showed them a few pics and gave them a link to this page. All companies have been very impressed with the craftsmanship! One company said their products basically weren't good enough and another one wasn't interested at this time. That company was Borla. Borla supposedly makes really high end stuff and its all 304 stainless with internal packing consisting of a continuous roving ceramic fiber. Because of this they claim the mufflers never burn out and don't require any steel wool wrap around the perforated core.
Well, while I was waiting on Borla to get back with me I ordered a 2 into 1, 2.25" dual into 3" single Borla Pro XS muffler. Here is what was delivered.


Can you see the big ol blobs and how far the perforated tubing is protruding into the 3" pipe?

While I am a little bummed Borla didn't want to play ball with comp'ing me mufflers, at least they made good on this defective muffler.
I called them and sent these pics in which they confirmed the muffler is defective and are sending me a replacement (currently in transit).

Well what is a semi retired mechanic/nerd/wannabe engineer going to do with a brand new 304 stainless steel defective muffler? CUT IT OPEN AND MODIFY IT!!!

My original idea for this muffler was to see if it is feasible to make a resonated merge collector. Yes it would be longer than my original y-pipe so power characteristics would skew to lower rpm (this could be a good thing for cruising fuel economy). Also of concern to me is would a resonated merge collector restrict the scavenging effect of the merge collector at all due to the sound and pressure waves bouncing around in the muffler?
This is not currently planned as an option for future y-pipes yet but it is a possibility if it works well. It is also an expensive addition as it involves 2 extra v-bands, 2 flex pipes, no jig, etc.

Well, since I have a muffler to modify this is its progress so far:


Stainless steel wool for forever durability.

This is the shortened muffler. I cut off 2.25" off of both tubes and welded it back together.
The 3" by about 1.25" piece was the original merge collector. It attached to the perforated tubes on one side and the muffler case end on the other. In the picture you see the new transition cone I welded on after cleaning up the original blobs of welds in the merge area.

Here is the merge collector after I got done with it.

This is the new merge collector area. The case is welded to the first 3" to 2.5" transition cone, then another transition cone to bring the exit back up to 3". This is to harness Bournoulli's principle pertaining to venture effect. Theoretically since each exhaust pulse will perfectly alternate between each tube, there will be zero restriction at the merge exit BUT with high venture effect pulling on the opposite tube.

I have wrapped it semi tightly with the stainless steel wool and I am going to finish packing it with the Borla ceramic packing I saved. I plan on packing it pretty tightly which theoretically will decrease muffling efficiency but equally important to me is preserving the precious exhaust pulse by not letting it expand too much into the surrounding muffler body.

All for now but I am still working y-pipes and will have @Basikbiker's finished very soon. @JacksonTacoma, I will send you my y-pipe if I have to in order for you to follow through with your plans. Please keep me updated on when you need it.

I would also like everyone to think of those deployed and or are working in the desert. I know there are at least a couple people that visit here that are currently deployed. You know who you are!!! Stay safe and return with more Roostability!!!

 

This is the stainless portion of the wrap. Its held in place with stainless safety wire preventing any shifting of packing over time.
It will also be filled with the original Borla ceramic packing then sealed up.

 

nice! had a borla on an M3 and loved the sound. THey make some good stuff....when its not defective.

 

I currently have the borla catback system, I put it on after installing the URD headers and I loved the sound. Had to add a vibrant resonator when I installed the URD y pipe to quiet the rasp .

 

Magnaflow 59905

 

I think you should see an MD for dat growth...

 

Don’t worry, the bulge doesn’t last for more than 4 hours. So I don’t need to contact my doctor.

 

What diameter is the system?

 

I believe it is 2.5” tubing.

 

@loginfailed @Roostfactor Nice! Place and position looks familiar!

 

You’ve spent some time laying on that same slab of concrete!

 

Definitely have gotten my rentals worth out of the driveway for sure! Not unlike many I'm sure.

 

And I just thought you were some rando when you wanted to sell me your URD cat back...