Much like a highway, todayís blog post will feature two things ó merges and exits. Simple-Title Tuesday.
First up, weíre back in the fabrication department after what turned out to be a very exhausting weekend. That didnít stop us from getting right back into the thick of things, though, so we were determined the finish the WRX LSxís custom long-tube headers. With the runners all welded into place on the manifold flanges, it was time to finish the bottom end of the headers. In order to keep the flow as laminar as possible inside the tubes, we made a bullet merge to put between the pipes inside the collector. This helps to better route the flow of exhaust gas, keeping power from being lost to turbulence. Hereís a quick shot of the bullet merge, independent of the headers:
After some quick welding, we had it on.
From there, we hoisted the headers back up into the engine bay, where we would tack on the merge collectors and make sure theyíre oriented in the correct position. The merge collector itself is the piece thatís welded on to the end of the header, and helps to channel the exhaust gas flow from four individual runners into one single exit. Making sure the collectorís angle is proper, ensures that we wonít have to create extraneous bends in the exhaust itself, which will sacrifice power.
About halfway through welding the collectors on, we set them aside to cool. Once they got down to a better temperature, we finished off the welds, and now weíre just about set to work on everything else thatís left with the build. Since the new rear subframe that came with the car has a bit of fitment issues, you might be seeing a few more interesting fabrication projects coming your way soon.
Over on the other side of fabrication, the Accent is nearing completion. If you remember that hole we cut into the bumper just before Eurowerks, weíve finally found a use for it. If you havenít guessed by now, itís Danís new exhaust exit. Merges, exits, get it? Weíre just so bloody clever. But, we digress; hereís a quick shot of Danís exhaust rear section in its final location.
As you may have also guessed, these pipes donít just magically fuse themselves together. It takes elbow grease (not literally), some argon, electricity and a couple other items. In other words, it takes some TIG welding. Which, as you know, we tend to photograph extensively. Hereís a taste, as weíre saving the rest for the Accentís final post.
Weíre almost to the end with Danís Accent. But if you know us, you know we wonít be finished when itís just an exhaust pipe hanging out of a bumper. Nope, not at all. Get ready for the stunning conclusion of this series very soon!