my brother in law is doing a big house shift, so I scored a few boxes of mostly Mk1 parts.
I now also have wiper arms, sunvisors, and a bonus secondhand windscreen.
It cleaned up suprisingly ok, so its slung in temparary for now with some tape, to keep the dust and stray paint down.
The best part is it came with rego already, 1980's style.

It was stinking hot Saturday, perfect weather to do some welding.
My first ever exhaust is taking shape, and of course I used the gasless mig to try doing stainless.
The tube and bends were just lying around ready, and before I knew it, it was time to bite the bullet and give it a crack.
I dont think i'll pass any welding ticket, but so long as the van doesnt end up sounding like an old Fergie, I'll be happy.

 
I'm still figuring some of the layout in the pics, and need some brackets to finish off, but overall I'm pretty pleased with how it is turning out for a first attempt.

the metal drop saw made easy work of trimming the Ali express bends down, better than an angle grinder could do.
 
By using the flexi joints, I found it leaves some tweakability in the joints until it's all squared up properly, as I learnt you can rotate the bend around (of course) to let the muffler align parallel with the floorpan for example.
 
Same with the loopy bit over the diff. I just eyeballed a couple of the bend angles, and made sure to cut them so that the cut remained circular. I have new respect for guys who do this for a living.
That or they have a pipe bender!
 
I should have 3D printed a cutting jig.
https://www.printables.com/model/1073313-51mm-pipe-bend-elbow-cutting-jig 
next time!
 

1. We got ours from a exhaust shop in NSW, sells ss pipe by metre cuts , the 90 angles are chinee. V bands from eBay or Ali ( all comes from China anyways)

2. 0.6mm wire will be more weldable as the tube is 1.2mm wall .
Pure argon for stainless , some say CO2 can be used but stick with argon.

2.5, I was using 0.8 SS MIG wire as Tig filler rod on my Focus exhaust, much cheaper and worked fine when it was needed .

do it Mark!
MArty gave me links for the hotdog and main muffler, just from Alli. 
Honestly, they were so cheap!, and the bends too.
 
Cough cough, of course I just used the mig, with no gas, and same wire as i've done all of the welding, still on the same spool. So in short, do exactly nothing different.
Didnt even change the welder settings ( to be fair, I must have been welding something a little chunky previous).
It was hot enough, as I accidently blew through when my technique was a bit off, so that was good in a way. I checked the penetration from inside, its solid though, well looks it.
My tube was from a local guy i found on Gumtree actually, who sells exhaust bits on the side, it is "Redback" stuff, and it was a bit easier to get a 3metre length of 2.5" stainless from him than from online via the postie.
 
I bought a V welding tig welding clamp that holds 2.5", and has slots to weld through, and that made it a little easier to position. With good cuts, linished back a little before welding, and some patience, I'd absolutely do it again.
No need to take the car anywhere as well. I just wish i'd have had something to copy from, rather than just winging it. I have done no welding under the car to make it either, just position it, mark with texta, then set it on the bench and weld. It might die in the rse come the first bumpy road, but I'll just reweld it! :)
 
I'll post a finished pick once I can get to the local shop to get some hangers and finish off.
Plus I can soon run the engine cam in now, with an exhaust fitted.
 
 

Thanks guys, just absorbing your comments.
 
I definitely want the system to be 'pull apartable' to some degree. So will need some expanded ends?
Also pondering a side exit if I can keep it quiet enough?
 
Marty, I don't pull the MIG out enough to warrant the foray in to TIG. That being said I've used half an E bottle of argoshield light this week. Been researching gas options and I think I'll try mine first before I go and buy a bottle of argon.
 
Probably easier if I draw the system up with a pic or two and post it here for comment and advice.
 
Would be good to see the type of clamp you used Deano. I've seen a few types in videos.
 
Mark
 
 
 
 

I just placed an order online from another mob.as I could not get around to the local shops.
Plus like Repco wants $18 for what you can buy $5 from these guys
 
Pricing seems ok on alot of the stuff, and black Friday sale is on
https://www.exhaustshop.com.au/ 
 
My tube was 2.5" (63mm) stainless, because MArty found htose bends cheaper (x6 stainless, about $50?)
I just used 1 x Vband at the end of the extractor, the main help is 2 of the flex couplings, as they give you the fudge factor when assembing, as they slip over the exhaust and pipe, so less butt joints too.
 
Have to wait a few days now to finish  off, lucky I have heaps of other jobs on the list.