2nd Gen JCW R56 JCW - Build Thread - New Set Of Pipes

Discussion in '2nd Generation: 2007+ R55 through R61' started by Metalman, Jan 19, 2011.

  1. Justa Jim

    Justa Jim Well-Known Member
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    I know the angled cut is in, but I like the squared look better. Not sure why exactly, but I think it looks cleaner for some reason.

    Jim
     
  2. Metalman

    Metalman Well-Known Member
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    Well.............
    I guess I could make one side bias cut and the other side square cut. :eek:
     
  3. Justa Jim

    Justa Jim Well-Known Member
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    You sure could. Then it would look like the nose turret on a Cobra helicopter, with a mini gun and a 40mm grenade launcher side by side. :cornut:

    Jim
     
  4. Rixter

    Rixter Well-Known Member

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    I've been trying to achieve that look for years but never quite succeeded
     
  5. Justa Jim

    Justa Jim Well-Known Member
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    :lol::lol::lol:

    Jim
     
  6. Bigprfed22

    Bigprfed22 New Member

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    #126 Bigprfed22, Feb 14, 2011
    Last edited: Feb 14, 2011
    Im so envious of what you do :arf:

    I'm a key board jocky and used to be a wrencher(still am for the side jobs) but design is definitely a passion. Awesome work!

    btw , i wont mind a drive up to ohio when you take of your jcw factory exhaust hint hint:cornut:
     
  7. Metalman

    Metalman Well-Known Member
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    Thanks for the kind words.... I've always liked making things with my hands. Coming to work every day never seems to be a choir. I have great employees and loyal customers, what more could someone want?.

    The original exhaust will be packaged up and stored back in the corner of the shop for the eventual day I sell my MINI.
     
  8. Metalman

    Metalman Well-Known Member
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    Just received my SS flex joint from TH Motorsports. Price $34.57

    As suggested by Keith Huevo, this design creates less exhaust turbulence than the corrugated flex joint.

    Thanks Keith for the suggestion.

    Chuck


    [​IMG]

    [​IMG]
     
  9. iwashmycar

    iwashmycar Active Member

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    looks like youre about ready to go!
     
  10. iwashmycar

    iwashmycar Active Member

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  11. Metalman

    Metalman Well-Known Member
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    Hah....
    I was down at the shop yesterday, met Allen (rigidjunkie), and helped him with his bicycle issue. Another buddy that owns a powder coating operation also stopped by for a little R&R and metalworking.

    Afterwards, I spent some time working on the exhaust. Cut the two 4" canisters that will make up the rear muffler. I have a couple of 90 degree mandrel bent elbows that will be merged into a "Y" that will feed into the two 4" muffler bodies.

    Unfortunately I've been slammed with work going through the shop, so my progress on the exhaust has suffered. I might sneak off today and try and get some more work done.

    Chuck
     
  12. iwashmycar

    iwashmycar Active Member

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    cool cool. Just happened to start wondering about the progress lol.
     
  13. Metalman

    Metalman Well-Known Member
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    OK.....
    I've come to a kind of crossroads with part of the design of my custom exhaust.

    At this point I'm currently staying with the stock downpipe during the warranty period. For the most part this experimental exhaust from the cat back will be a straight through exhaust. I'll venture to say the most restrictive part will be the stock downpipe, with cat being the biggest contributor to exhaust back pressure. I chose to go from the stock 2-3/8 tubing size to 2-1/2, in an effort to reduce back pressure and have a muffler design with baffles that can be easily pulled and changed to adjust the sound level. Reduced backpressure should allow the turbo to spool up faster.


    So todays question has to do with the effects of exhaust backpressure on a turbo charged engine....

    If I had a way to adjust backpressure from say stock to wide open, what might I expect to see in the way of change?

    Any thoughts on what might be expected?

    Chuck
     
  14. Rixter

    Rixter Well-Known Member

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    Chuck also as far as reducing pressure, have you gotten rid of the stock hot-side discharge pipe in favor of NME or some other variant?
     
  15. Metalman

    Metalman Well-Known Member
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    No, everything is still they way it came from the factory.
     
  16. Rixter

    Rixter Well-Known Member

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    That would seem like a fairly quick/inexpensive win
     
  17. iwashmycar

    iwashmycar Active Member

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    I noticed a lack of low end power with the Stratmosphere I had, which I feel had very little back pressure. Had (and still have) the stock DP on. Once I put the stock S exhaust back on I liked it a lot better (off the line accleration). The factory JCW exhaust felt just like the stock S one as far as turbo-spooling pressure goes.

    I dont exactly know the logistics of it, but the Strat system was 2.75" i think. JCW is closer to 2 1/8"
     
  18. Metalman

    Metalman Well-Known Member
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    Thanks Adam....

    I was thinking of adding a vacuum or electrical operated exhaust cut-out. Now normally cut-outs are used to dump the exhaust gases outside the exhaust track. But my thoughts are to keep the cut-out in line with the exhaust continuing to flow through the mufflers. I would then modify the butterfly valve (a simple disc on a rod), by removing metal from the disc so when it's closed the the gases would still pass through the butterfly valve but at a rate similar to the stock exhaust of 2-1/8" and when open it would be similar to the 2-1/2". So with the flip of a button I could go from stock back-pressure to custom straight through back-pressure.

    I'm also thinking that if there was an issue with the irritating droning noise entering the cabin, this could possibly alleviate it.

    Anyway, that's what I had floating around in my head.

    Chuck
     
  19. iwashmycar

    iwashmycar Active Member

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    Interesting thought. I guess it just depends what sort of difference it makes. Only one way to find out though
     
  20. Bigprfed22

    Bigprfed22 New Member

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    Greate motive but i know that most butterflies in exhausts are built in to the mufflers not the initial pipe. I wonder how that would affect the performance, you could probably get a patent for it :Thumbsup: I cant wait to see what you come up with, i just wish i had the materials and machinery needed to make protoypes.:Thumbsup:


     

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