- Careful measuring is an absolute must when working with exhaust tubing, especially at angles. Measure under the vehicle first to get an idea of how much tubing is necessary and where you need the bends. Measure it out on the actual exhaust piping and mark where the cuts are needed with a black permanent marker or tape. It is a good idea to measure everything twice before you mark it, because a bad cut could mean more money spent on exhaust tubing.
- Cut the exhaust tubing in the places you have marked. Remember that angles must be cut opposite each other, so plan ahead carefully for this stage. A reciprocating saw is one of the best exhaust pipe cutting tools, but if you do not have access to one, an angle grinder with a cut-off wheel installed will work. Cut slowly so that the lines stay straight. When all the pieces are cut, mock it up under the vehicle to make sure it is going to fit the way you want. Make adjustments as necessary.
- Once the tubing is cut to the desired lengths and angles, weld them together. Remember that most exhaust systems are stainless steel, so you will want to use stainless wire as well to prevent rusting along the welded areas. Since the exhaust system is going to bend (either around an axle or routed from one side to another), it may be necessary to weld it up under the vehicle. Be careful, and clean up any oily or fuel-covered surfaces before welding begins. Start at the engine side and work your way back. Tack welds should be placed all around the tubing first so that warping is prevented. Once the system is tacked in place, you can go back and weld completely around each joint. Do not skip places if possible, because an exhaust leak will be the result, which could affect smog checks or performance. If you are installing a muffler as well, make sure the flow arrows point to the back of the vehicle so that the exhaust is not impeded.
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