Here are a few more pics that should show how I approached the design. Also here is a short list of parts I used in the build.
From Summit:
(1) MPE- 12265 Magnaflow Muffler
(1) MPE-59926 Catalytic Converter
(1) WLK-42432 Dynomax Pipe
(1) SUM-G2990SS O2 Bung
From Burns
UB-250-40-16-321 (321 U pipe for tips)
From McMaster-Carr
(1) 5276K42 Constant Tension Tbolt hose clamp
(1) 5276K43 Constant Tension Tbolt hose clamp
From Verocious Motorsports (I found online)
(2) 3-Bolt 304 SS Vibrant Exhaust Flange
From our Host
New exhaust gaskets and copper M6 12mm exhaust nuts
From RarelyL8
Carrera uncut fiberglass rear bumper valance
From MetroMods (ebay)
UNIVERSAL BLACK ALUMINUM MESH GRILLE GRILL 12" X 48"
I used the stock cat pipe collector, cut it off the stock cat and welded on a short piece of straight 304SS tubing that was flared to accept an inserted tube. I had this piece from another project. Then came the new cat fitted to the new flange. I fabbed this in place with the stock muffler acting as a jig so the flange would be in the correct location. Then I removed the stock muffler and began working on the new muffler.
On the muffler I used the 321 SS tubing for the outlets since they would be visible 321 turns a nice gold color when heat cycled. I used SS wire in my MIG to keep it all in the family. I had to cut the outlet flanges off the muffler body because you have to make a tight 90deg turn to keep the tips inside the bumperettes.
The trim rings I made out of 1"x1/8" steel strap. I cold formed it around a gas cylinder safety cap that I tack welded to my welding bench (4" OD). I welded a tab on the license plate side to attach the trim rings to the bumper. The mesh is held on the back of the grill with epoxy. I cut the holes in the bumper with a jig saw (very carefully) and protected the paint with masking tape. I cleaned up the cuts and did the final fitting with an pneumatic rotary deburring tool.
All in it took a full day of disassembly, fabbing, and final detailing, and I am still not finished with the paint work on the lower valance, and I haven't installed the seal between the bumper and valance yet (waiting on paint).
