Welder
Yesterday I finally got round to buying the welder + gas I've been promising myself for 3 years or so. I bought an R-tech one based on good internet feedback, 2 year waranttee that is actually upheld, a couple of recommendations from people I know and the fact that the company is local to me.
Some of my first aluminium welds:
The objective is to learn some man skillz and to build a few miscellaneous things like a breather tank and importantly an exhaust that can get noise down below 105 dB, ideally below 100 dB.
Exhaust Design
This is my initial design/experiment made from 3" tube and sheet steel. It differs in design from any standard exhaust box for the VX220, this will reduce extra unnecessary pipework (weight) and make the gas flow round less bends.
Entry into the box will be perpendicular to the box, this eliminates 180 degrees of extra bend (where the OEM system routes via the cat into the side of the OEM box). On initial entry into the box the stream will be split by a Y-pipe with the top and bottom split mounted on a vertical plane. Then internally, the 2 paths of exhaust gase will travel down perforated pipes with bends, one path higher up in the box and one lower down in the box. This will naturally lead to the tailpipes which will exit the box in the standard config.
I plan to make the box very long, fairly wide and deep, such that it has a large volume. There is an option to possibly fit an electrically controlled butterfly flap and straight through pipe from the inlet Y to one of the tailpipes. This would yield almost no noise cancellation, but the maximum power, noise & flames. A switch could be mounted on the dash to open/close this config. The issues are I don't know if I can trust the longevity of these electro-mechanical butterfly flaps and also it will make the car run lean as there will be less back pressure (perhaps this can be dynamically mapped with some enrichment "flag" when the bypass switch is activated).
My design/thinking is the advtanges of this design are:
1. That splitting the exhaust into 2 flows internally will halve the exhaust gas speed giving more time for waves to bounce out.
2. Two paths (roughly a mirror image of each other) might help cancel out noise waves.
3. There will be a lot of perforated pipework (much more than any usual straight though box).
4. Box ends will be resealable, perhaps double skinned as the gas will be striking the ends the most.
5. Bends in the box will be made from sectioned perforated pipe (probably).
6. All internal pipes to be wadded.
If you have some useful input/suggestions, please fire away....
Edited by Nev, 24 July 2015 - 06:22 AM.