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Fabrication
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General Fabrication
We offer TIG
welding of aluminum, stainless steel, and mild/aluminized steel; plasma
cutting, and water jet cutting. We will make whatever part you need, if
you can think it up in your head we’ll find a way to make it fit. For
the most part we make exhaust systems, intercooler piping, intercooler
end tanks, and intake manifolds. Although we can make anything you
want; for example, battery trays, catch cans, control arms, sway bar
mounts, camera mounts, or seat bases. Our goals with any fabrication
project are to use the straightest piping possible, maintain ease of
service, and keep everything aesthetically pleasing. Quality is also a
high priority; we do not let anything leave the shop that would not put
on our own cars.
As for pricing our shop rate is $75 per hour.
How much will a one of a kind air to water IC setup cost? That’s a good
question; we need to look at the car to give you a real quote. Without
looking over the car with you in person we cannot give you an accurate
price. It also gives a good chance to go over every option with you to
make the parts fit the way *you* want.
We do not make half ass
parts, don’t waste our time calling asking for a quote and compare the
price of a custom one of a kind stainless part to some mig welded, mild
steel, POS that some kid makes in his garage and sells on ebay. We
design each part to fit YOUR car, if you don’t mind taking off your o2
housing to change your oil filter, or completely unnecessary 90 degree
bends then you can buy the junk that other shops sell.
See the Sidebar Pictures for Examples of our Fabrication Work.
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Exhaust Systems
Piping:
We offer
mild steel and 304 stainless. Mild steel is cheap and it works, it also
rusts. You can paint the exterior to help, but it will rot out from the
inside in a few years. We prefer to use 304 stainless; it will last
longer than you car, and continues to look good a decade later. Mild
steel is always an option if that’s really what you want.
All our systems are mandrel bent, if you want a press bent exhaust talk to a muffler shop.
We also offer a variety of reducers and y sections Link to catalog
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Flanges:
For our 3” pipe, o2 housing
flanges, and Mitsubishi turbine housing flanges we have ½” thick
stainless. Our 3” flanges are three bolt only, the two bolt flanges
have a tendency to warp over time and start leaking. That is also the
reason why we use such thick flanges. For 2.5” exhaust systems we use
3/8” two bolt flanges.
We also offer 304 stainless v-band
flanges and clamps (also full stainless) in 1.5”, 2”, 2.5”, 3”, and 4”
sizes. They are the fastest disconnecting clamps available, just remove
one nut and you are done. Perfect for downpipes and test pipes.
The
flanges seal so tightly that no gasket is required. The best thing
about these flanges is that they are actually cheaper than our standard
three bolt flange when you add in the cost of the gasket and hardware.
At only $40 a set these are much cheaper than anything else on the
market.
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Mufflers:
We offer the full line from
magnaflow, flowmaster, allied, carsound cats, and dynomax. We normally
use magnaflow mufflers as they are the highest flowing and best looking
mufflers at a good price. For those concerned about weight we use
Burn’s stainless mufflers, between 2.5 and 3.5lbs and only $200. We
also have a 3” inlet dual 2.5” muffler for those of you that want to be
stealthy, or just don’t like a 4” tip. For some examples check the DIY
section of our catalog. Link to catalog
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Steve, Evo VIII
The Evo is a great car
from the factory, but like any production car it has room for
improvement. This is pretty evident when you look at the stock exhaust,
there are a lot of bends that simply do not need to be there. Our Evo
exhaust is 3” stainless from the o2 housing back. We drop the front
subframe brace slightly to get clearance for the 3” pipe, while
eliminating three bends. From there it has a carsound high flow cat
with 3 bolt flanges, a test pipe for track use is also available. Then
it runs back to a straight through magnaflow muffler with an angle cut
4” tip that looks almost identical to the stock exhaust tip. This is
the exhaust we made a jig of for our production units **link to EVO
exhaust in catalog** Link to 2003 Mitsu EVO8
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Andre, 91 Galant VR4
Andre has a
full 3” from the turbine housing back ending in a dual square tip
magnaflow muffler. The two square tips fit the rectangular opening in
the jdm bumper perfectly. The o2 housing still allows clearance for
removal of the oil filter, a common problem with o2 eliminator type
downpipes. It is flanged at the oil pan for easier service of the
transfer case.
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96 Eclipse GSX
Unlike the other
systems this was made with no stealth at all. The least amount of bends
possible and a N1 style muffler mounting. It has a total of two bends,
yes only 2 bends. One bend at the downpipe, and one slight bend at the
rear diff. 3” from the o2 housing back, full stainless, and a magnaflow
muffler. We also made a new dump tube for the tial 35mm. It comes out
the front bumper.
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Intercoolers and Piping
We offer the
best custom intercooler piping you’re going to see anywhere. Put the
powder coater away, set down the buffing wheel and polish compound. Our
304 stainless comes to you already polished to a great sheen. The 304
we use is much higher quality than what you can get from a standard
muffler shop. It butt welds perfectly, no filler required. This means
you get a very narrow weld bead, with good penetration that looks
awesome. As for intercoolers we normally use garrett or spearco cores,
they are a bar and plate design, durable, and have a good fin count. We
have also used spearco, xs engineering, and Apexi cores. If you have a
1G DSM, 2G DSM, or EVO VIII please check our catalog as we sell kinetic
motorsport intercooler kits for these cars much cheaper than you can
have a custom setup made. We have used a variety of blow off valves and
prefer the HKS super sequential over the others we have used. It is a
pull type valve so the higher boost you run the tighter the valve
seals. Due to this they do not need to run an overly stiff spring,
giving it better operation at low boost/part throttle. On the Evo VIII
we recommend the greddy type S though, as the HKS has a surge problem
on that particular car.
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Steve, Evo VIII
While the EVO comes
with a front mount intercooler from the factory, it is still a factory
piece, and production design restraints mean it is not optimized for
performance. Aside from the fact that the core itself is not very
large, it’s tubes are very small. That means greater pressure drop
across the core and a bigger airflow restriction. The piping is
downright sad, with a dinky 2” pipe for much of the lower pipe. The
upper pipe has more bends in it than an autoX course, a total joke. We
use a kinetic intercooler core, one of the biggest true bolt on cores
available for the Evo, it comes in at 24x12x3.5”. That’s over 1000
inches of core volume. It really bolts on, no cutting of the car
required. The lower IC pipe is also from kinetic and is 2.5” 304
stainless. We then made a small battery tray and used an odyssey dry
cell battery to get more room for the upper IC pipe. The new upper pipe
follows a much more direct route to the throttle body than the OEM
junk.
Link to More Pictures of Steve's Evo VIII
Link to Fabrication Process of Steve's IC
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Mark, 91 Galant VR4
Mark has one of the
cleanest Galants out there, now that he has our intercooler. Mark
wanted to get rid of his small fmic piping and use a shorter routing
layout. Since his old intercooler would need new endtanks for the new
piping, he sold the whole old setup. He picked up a 2-216 spearco core,
28x12x3”. This is a very long core for a gallant and it made getting
the pipes to the endtanks a little bit difficult. After playing with
the core location for a while we found a way to make it all fit with
the stock AC fan, jdm bumper, and jdm foglights. It’s one of the only
gallants you’ll see out there with this core behind a jdm bumper. The
piping is also much shorter and direct than his old setup.
Link to the Build of Mark's FMIC
A quote from Mark on the GVR4 board:
“I
don't trust my car to anybody, so me leaving my car at his shop for two
weeks without worry is really saying something. Other than a few ideas
I threw out to him on how I wanted it to look as far as piping and core
mounting Andre did all the work and I couldn't be happier. Whoopha”
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