Delica Canada | Mitsubishi Van Club

Just though I would share some pics and info on my side exit exhaust my friend welded for me this past weekend.

Parts:

4" Magnaflow round muffler Part number 10416 from amazon.ca: $100
Two 45 degree 2.5" stainless mandrel bends from Columbia River
One straight stainless pipe 2.5" from Columbia River
One 2.5" 2 bolt stainless flange from Columbia River (the Combined piping and flange was $145)
One 12" long straight stainless rod for the exhaust hanger from mufflertech: $15

I apologize I didn't take pics of the whole process.

I had a bolt spacing of 92mm and read on the forum that a 2.5" flange would work. We had to grind out the bolt holes on the flange a bit as they were too small.

The 45 degree bend off the downpipe/turbo manifold was not ideal as it angles down a bit too much. We compensated this a bit by cutting off two inches off the top of the first bend. Other than than, it was the perfect amount of piping.

Bent the rod with a torch and vice for the exhaust hanger. Used the drivers side original muffler hanger mount.

I haven't put a gasket in yet but doesn't appear to be leaking.

Noticeable drop in EGT's thus far. ~100 degrees maybe. Also sounds pretty cool. It wasn't even that loud when I fired it up without any exhaust on.

Nicely done! I'd love to have made mine out of stainless, but I'm too cheap to buy the TIG welder to do it properly (and WAY too cheap to pay someone else to do it!)

Way cool

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I'm about to do this job. Is the exhaust flange just sitting flush against the turbo mount? I ordered 2 flanges just incase I have to use one as a spacer.

Cheers

Just check with your province regulation: here in fuc... Quebec, if you have side windows that have the capability to be open, the modified side exhaust is not alloud....We already have to be more carefull than other cars as RHD owners, I will personally not push it to be caught doing this mod, as for now :(

Lapprentis

north54 wrote:I'm about to do this job. Is the exhaust flange just sitting flush against the turbo mount? I ordered 2 flanges just incase I have to use one as a spacer.

Cheers

Yes it is flush. I did not put in a gasket either and doesn't seem to be leaking.

I should add that I got dinged with FedEx charges after the fact so it was a bit more expensive. I can't remember how much it was though.

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takeuchi wrote:

north54 wrote:I'm about to do this job. Is the exhaust flange just sitting flush against the turbo mount? I ordered 2 flanges just incase I have to use one as a spacer.

Cheers

Yes it is flush. I did not put in a gasket either and doesn't seem to be leaking.

I should add that I got dinged with FedEx charges after the fact so it was a bit more expensive. I can't remember how much it was though.

Sent from my ONE E1005 using Tapatalk

Thanks Takeuchi, any trouble with BC regulations on having a side exhaust? I can't find anything that prohibits it in the motor vehicle act so far.

north54 wrote:

takeuchi wrote:

north54 wrote:I'm about to do this job. Is the exhaust flange just sitting flush against the turbo mount? I ordered 2 flanges just incase I have to use one as a spacer.

Cheers

Yes it is flush. I did not put in a gasket either and doesn't seem to be leaking.

I should add that I got dinged with FedEx charges after the fact so it was a bit more expensive. I can't remember how much it was though.

Sent from my ONE E1005 using Tapatalk

Thanks Takeuchi, any trouble with BC regulations on having a side exhaust? I can't find anything that prohibits it in the motor vehicle act so far.

I did not check

Sent from my ONE E1005 using Tapatalk

I actually did this project a few weeks ago and it is not that easy for a few reasons.

Flat exhaust flange is not a great mate to the existing ball and socket manifold: With the flat exhaust flange you give up some margin for error and misalignment issues that might come up. I personally ordered the 3/8 thick flat exhaust flange and due to the large difference in thickness the flange gets pretty hot to make the weld to the pipe good which resulted for me in a slightly warped flange. Going the ball and socket route with an expander to take you up to 2.5 inch would solve this issue and works with the current design of the manifold and gasket. Its not that a flange wont work but it has to be absolutely flat to make sure you don't get an exhaust leak.Personally Im thinking about cutting the flange off my exhaust and doing the ball and socket to solve my small exhaust leak issue.

2ft straight pipe section instead of 1 ft: Order a 2 ft straight section instead of 1 ft if you want the exhaust to stick out beyond the rear right tire. This way you can also cut it to the length you like and the angle you want.

Make sure to account for engine movement: When my car fires up the engine torques pretty good and exhaust taps the rocker a few times before it settles into a nice idle. give yourself a good inch and a half from where the tailpipe exits, and have several exhaust hangers that fit well to combat shaking.

Differences in outside diameter between mandrel pipes and exhaust and flange: There is considerable difference between the exhaust and mandrel pipes and flange almost a 1/4 between pipes and exhaust. As soon as you put down a tack the 304 stainless will just suck up to the side of the weld and you will have a pretty big gap to fill on the opposing side. You can get a tailpipe expander and make up a little of this room but it isn't perfect.

Make sure to purge: Purging argon 10-15 cfh to prevent "sugering" the backside of you weld causing oxidation and creating a weak point. i have included a good video for this.
https://www.youtube.com/watch?v=m2E_PAgoGSE

This is not the easiest thing to attempt so take your time.

I will say that doing your exhaust upgrade brings you exhaust temps way down, car has a noticeable amount more power but not much, mostly noticeable when accelerating from standstill.