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Rear Bumper/ Exhaust arrangement

Single 4" exit, R32 bumber, carbon wrapped diffuser, burnt stainless tip
1 (14.3%)
Twin 3" exits (left) R32 bumper, carbon wrapped diffuser, burnt stainless tips
6 (85.7%)

Total Members Voted: 7

Author Topic: Tornado Red ED30 - Winter update: Brakes/tyres/Home made valved exhaust  (Read 24522 times)

Offline cuprajake

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Re: Tornado Red ED30 - New Pics
« Reply #60 on: January 17, 2015, 11:39:35 am »
lol the joys of living up hills lol

you weren't at Rochdale mac donalds a few week back were you?
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Offline ed30sam123

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Re: Tornado Red ED30 - New Pics
« Reply #61 on: January 17, 2015, 11:50:07 am »
lol the joys of living up hills lol

you weren't at Rochdale mac donalds a few week back were you?
Yeah it's a nightmare mate! How are ya? Might bring it down for a machine buff in spring, I don't trust myself! No I wasn't, I don't often go your way
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Offline ed30sam123

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Re: Tornado Red ED30 - Winter Update!
« Reply #62 on: April 15, 2015, 08:00:54 pm »
Evening all!

Haven't updated in a while so I thought it was time to show you what I've been up to!

Had some great fun in the car over the winter, I was dreading the snow with the DSG but i was actually really surprised how well it did! I got properly stuck once (bear in mind I ran Eagle f1's through winter) and 5 mins of digging and it was out!



The back offside tyre was more worn than the other side so I replaced the axle with Eagle f1's



Last week I replaced the fronts with Michelin Pilot Super Sports which I am over the moon with! Noticeable improvement and from what ive read and heard they are supposed to last longer than the Eagle f1's aswell  so its a win win  :grin:



At the beginning of the year the year I put my S3 brakes on which have given me a bit more confidence. Running standard S3 pads and again a noticeable improvement. Not 100% sure what my plan with brakes is yet, fund dependant I will be going for a bigger, lighter set up along with alloy hubs and lower arms.




Finally, over the last couple of weeks I have been building my own 3" Stainless exhaust system. I wanted the car to sound great when I wanted it to but I didn't want it to be intrusive. So I designed a stepper motor actuated valved system which allowed me to more or less adjust the tone of the exhaust.

First thing to arrive was the valve which I got from California, as you can see it was integrated into a stainless section which I didn't end up using.




Next up was the silencer and muffler which I got from Demon tweeks.

Silencer: Jetex/Simons 250mm 3"

Muffler: Flowmaster Pro Race 50 series 3"



I then went to a stainless steel suppliers and bought a load of 3" tube and bends. I had already drawn up the design so next thing was to make a cardboard template, the design changed slightly from what is pictured.



Once I was happy everything was right I cut all the tube to size and tacked it all together. (to all you weld nerds I am well aware my welds are terrible but it is my first attempt and I was welding stainless with MIG!  :ashamed:)



Here is the system fully welded, the orientation of the valve changed to allow room for a hanger.



and a shot of it positioned under the car


The hangers were then tacked on and it was fully welded up.

The switch was installed in the ashtray and the wire was routed to the back and through the wheel well with a gromet and silicone.




Here is the system installed, Please note it is not fully finished yet. I am undecided on what the plan is for the exit, im going to set a poll up and see what you guys think.

4" single exit (modified r32 bumper)

Twin 3" exits (modified r32 bumper)



It sounds insane with the valve open (silly loud rally car style :party:) and when its shut when on WOT I would say its quieter than the standard pipe, a lot of turbo noise though.

Hope you like the mods so far. RS4 FPRV should be here shortly then I will be going stage 2+ at some point.

Here are some local pics of the car







Thanks for reading, apologies for the rushed post!


Tornado red ED30 No. 0728

Offline v4rley

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Re: Tornado Red ED30 - Winter update: Brakes/tyres/Home made exhaust
« Reply #63 on: April 15, 2015, 08:06:33 pm »
Fantastic work! Had recently discovered those exhaust valves online not many about in the UK, great would love to hear a video when all sorted  :drinking:

Offline ed30sam123

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Re: Tornado Red ED30 - Winter update: Brakes/tyres/Home made exhaust
« Reply #64 on: April 15, 2015, 08:15:00 pm »
Fantastic work! Had recently discovered those exhaust valves online not many about in the UK, great would love to hear a video when all sorted  :drinking:
Thanks mate :D, Yeah I couldnt find one anywhere, im sure they are about though. It took 4 weeks to come and I had to pay £30 import tax!  :fighting:
Tornado red ED30 No. 0728

Offline KieranM

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Re: Tornado Red ED30 - Winter update: Brakes/tyres/Home made exhaust
« Reply #65 on: April 15, 2015, 08:16:17 pm »
Exhaust looks really good, can't wait to hear some videos! I have thought about doing something similar for a while.
How much did the exhaust cost you overall?

Offline dazza

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Re: Tornado Red ED30 - Winter update: Brakes/tyres/Home made exhaust
« Reply #66 on: April 15, 2015, 08:49:57 pm »
Love the exhaust. I bought a mig welder a couple of weeks ago. Any tips for a fellow newbie welder?

05 | Tornado Red | DSG

Offline ed30sam123

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Re: Tornado Red ED30 - Winter update: Brakes/tyres/Home made exhaust
« Reply #67 on: April 15, 2015, 08:55:03 pm »
Love the exhaust. I bought a mig welder a couple of weeks ago. Any tips for a fellow newbie welder?

What gas have you bought with it? I used argasheild. If I was to give you any tips at all it would be to take your time setting your welder up... power, wire feed rate, gas rate etc. just cut some off cuts and have a play about. Oh, and have a grinder on standby to grind off your bird sh*te  :grin:
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Offline dazza

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Re: Tornado Red ED30 - Winter update: Brakes/tyres/Home made exhaust
« Reply #68 on: April 15, 2015, 09:02:26 pm »
I was lame went for a no-gas mig welder. Plus think i would struggle to get the gas out here.

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Offline ed30sam123

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Re: Tornado Red ED30 - Winter update: Brakes/tyres/Home made exhaust
« Reply #69 on: April 15, 2015, 09:28:04 pm »
I was lame went for a no-gas mig welder. Plus think i would struggle to get the gas out here.

I couldn't comment on that really as I don't know how they would work? I know I ran out of gas half way through and it made a right mess!
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Offline dazza

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Re: Tornado Red ED30 - Winter update: Brakes/tyres/Home made exhaust
« Reply #70 on: April 15, 2015, 09:58:33 pm »
The MIG wire has a flux core which forms the shield around the weld to keep oxygen out.
The shield SLAG will need to be brushed off with a wire brush or chipped off with a hammer. The flux will cause some splatter i bought some anti splatter spray which should help to keep things tidy.

Did you build a welding table?

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Offline ed30sam123

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Re: Tornado Red ED30 - Winter update: Brakes/tyres/Home made exhaust
« Reply #71 on: April 16, 2015, 06:41:08 pm »
The MIG wire has a flux core which forms the shield around the weld to keep oxygen out.
The shield SLAG will need to be brushed off with a wire brush or chipped off with a hammer. The flux will cause some splatter i bought some anti splatter spray which should help to keep things tidy.

Did you build a welding table?

Ahhh interesting, I haven't heard of that before! Hope it goes to plan for you! No I did not build a welding table, I just tacked it all together then progressively welded it up with short runs to avoid it warping from the heat.
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Offline KieranM

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Have you got any videos of the exhaust?

Offline ed30sam123

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Have you got any videos of the exhaust?

The exhaust is off at the moment. I have machined my own valves and I am now putting two valves on to improve flow and noise. I will update with pics once I have have finished, and get you a vid of the sound.
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Offline Joshap1

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Love this car! It looks so good, I can't believe those springs were just a 15mm drop though!