Today, with the help from one of my employees (TIG welding Guru - because I can't TIG weld
) I completed the exhaust system. 
It took a bit of effort...and I'm stoked with the result. You may remember from an earlier post that I was using a JDM aftermarket NC rear muffler assembly. It had a 2.5" inlet that split into two 2.5" pipes. However, due to the higher flow requirements of my engine, a 3.0" front section is required. Two 2.5" pipes have about a 39% larger cross-sectional area when compared to a single 3.0" pipe. So I lopped off the 2.5" inlet and massaged a 3.0" to the profile of the 2 x 2.5" junction.Anyhow, before I got stuck into that I sorted a problem with the standard NC exhaust heat shield. The heat shield is an aluminised fibreglass moulding that had been damaged at some point and had sagged....problem solved....2 x oversized heat rivets.
Since the rear section of exhaust was stainless steel, I continued with the theme and had exhaust flanges laser cut (and machined where necessary).
Will all exhaust systems I make for my vehicles I use the good ol' masking tape to join the various bends and straight sections prior to welding it out....reduces the chances of a stuff-up.
Corndog - The TIG Guru
...after many hours this was the end result. This is the rear assembly with the 3.0" inlet and 3-bolt flange fitted.
This is the front section that connects up to the headers. Look Mum no cat!!!
.....fitted to the car. I'm stoked with the result.
I also took the opportunity to fit the Mazdaspeed front bar. It certainly provides a bigger aperture for ambient air to access the radiator.
By this time it was getting late, but I did get to fit the right hand rear footplate for the roll cage.
Can't wait of next weekend to continue with the rollcage.
Cheers,
Danny
)
