Exhaust tinkering

[MikkiJayne]

The D2 S8 has a donut-joint between the passenger side downpipe and cat, to allow the cat to be removed for access to the gearbox. Unfortunately most of them are looking pretty crusty by now, this one particularly so!



This is beyond salvation, and obviously unobtanium now - Prestige don't have any, and I don't have any good ones so time for a new solution.

Start with a 3D printed prototype to test fitment



That fitted the pipe quite well, so I sent the file to the local steel stockholder who CNC plasma cut me some flanges (minus small holes as the plasma won't cut them)



Drill mounting holes



Then stick it in the lathe and turn a chamfer in to one face to match the pipe



and then cut the lovely thing in half



Alas, this is the only way to get it on to the pipe.

Using the other flange, I bolted it all together to get it straight while back on the pipe. The pipe is covered in anti-spatter spray and I also used some aluminium foil between the new flange and the pipe so I didn't weld them both together.



Then attacked it with the mig, and we have this





I think this should work just fine, and I went slightly overkill and made it from 10mm plate, so it should last a few more years I need to do the same again to the cat which has the other side of this tomorrow, and then hopefully it will all bolt back together nicely

[Davey Blueeyes]

Flipping Nora. Wouldn't the world be a better place if MJ was in charge of it?!

Honestly, I think you are about five years away from restarting complete D2 production from Devon.

If you do I'll have one

[Sit down, Waldo]

There are so many threads on here that make me think 'What have I done?'

Are you really attached to your day job MJ?

[MikkiJayne]

Originally Posted by Sit down, Waldo

There are so many threads on here that make me think 'What have I done?'

#D2Life I plan to drive my D2 until the dinosaur squeezings run out, and I'll take as many others along for the ride as possible

Originally Posted by Sit down, Waldo

Are you really attached to your day job MJ?

I hate it, but it pays the bills and means that D2s can still be fun. If I did them full time, it would stop being fun

Finished this off just now. The second piece was much easier having learned a few things on the first. We end up with this:







Pretty happy with that, although yes, 10mm plate was slightly overkill 8mm next time, and make the centre hole a bit larger too.

[gninnam]

Very cool

[Sit down, Waldo]

Originally Posted by MikkiJayne

#D2Life I plan to drive my D2 until the dinosaur squeezings run out, and I'll take as many others along for the ride as possible

I plan to drive mine eventually

[Dezzy]

Hey you.


You should have said, think I have some more somewhere, I had them lasered, with the small holes