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  #1  
Old September 27th, 2015, 02:02 PM
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Custom exhaust predicament

I am finishing up this om617 swap and am about to drive the truck to an exhaust shop for fabrication of a custom exhaust. My old one from the 2.5 was rusted out!

The issue I have is that the local reputable custom exhaust shop does their own bends and doesn't want to do 3" because it's apparently more difficult to get the bends right and tight enough. They also don't do stainless. So I'm looking at a 2.5" straight exhaust with less durability and presumably less performance.

A local import shop will do a 3" stainless exhaust but they will use pre-bent ordered pieces to fabricate.

Reaching out to the forum to hear opinions on if the additional diameter and stainless is worth it. The custom shop has a good reputation. The local shop does exhausts occasionally for hot rods and what not
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Old September 27th, 2015, 02:14 PM
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If they don't salt your roads I think you would be fine with the non stainless steel. Also the original MB exhaust on that motor was far less than 2.5" in diameter so once again I think you will be fine.
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Old September 27th, 2015, 02:17 PM
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Yeah they salt heavily here - and I'll be here for another 3 years!
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Old September 27th, 2015, 02:35 PM
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The size is fine. That's what I have on my 2.8.

I did not go with stainless because I knew if the exhaust could potentially be damaged while off-roading, the extra cost of stainless was not justifiable.

Of course now someone gave me a Borla to put under there.
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Old September 27th, 2015, 02:38 PM
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Yeah they salt heavily here - and I'll be here for another 3 years!
If you are driving in the winter then go with stainless. I would call around and find a shop that will bend it up if you can find one. If not, welded up stainless macaroni bits will have to do.
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Old September 27th, 2015, 03:48 PM
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I did my exhaust with 2.5 mandrel bent pieces and butt welded them.

I am not so sure I would use a custom exhaust shop that doesn't use stainless. IMO the material isn't much more and for a good quality custom exhaust the labor would be the most cost. I felt the exhaust wasn't that complicated and a 3" tube could be made to fit. But I did do mine without a body on so maybe it was easier?
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Old October 6th, 2015, 08:28 PM
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First quote is in for a 304 stainless exhaust with one flex pipe and two couplers. $600 in parts and 12-15 hours of labor at $100 an hour. This seems exorbitantly high, especially the Amount of hours for this job.

Anyone have a perspective or opinion on this quote?
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Old October 6th, 2015, 08:34 PM
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What about get an off the shelf 110 stainless exhaust and just have them make the front down pipe to a cross over piece to match.
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Old October 6th, 2015, 09:51 PM
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Dave,
12-15 hours of labor is ridiculous. 3 hours tops and that is if he is a new guy and he only has one arm. 2 hours if he knows what he is doing and has two functioning arms.
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Old October 6th, 2015, 10:18 PM
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it should only cost between 3 and 600 to have a full system made. Depends if you can bring them the old pipes to use as a pattern, that will help immensely with the bending.

12-15 hours is kind of insane.

I have had both good and bad experiences getting custom exhausts done. There is a shop here that did the one under Yamelo, they basically fixed my bodged attempt to build a system. That was about $400. The system they built is tucked up nicely and doesn't rattle or rub. It is however getting bit rusty. But, it should all come apart and be modular since they did it using welded flanges.
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Present:
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  #11  
Old October 6th, 2015, 10:28 PM
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I am running a 2.5 inch straight pipe (love the sound) but not stainless. 12-15 hours!?! Wtf, is he a one armed muffler hanger?
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Old October 6th, 2015, 10:38 PM
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Ok... I'm no welder but sure thought that sounded absurd. Thanks for the feedback!

Surprisingly, this is a seemingly well-established shop.

Looks like I will end up going with a 2.5 straight aluminized mandrel-bent exhaust and hopefully save a ton of money. I hate to not do stainless but maybe it will make it 4-5 years around here!
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Old October 6th, 2015, 10:39 PM
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OK. My opinions:

If the shop has tooling for 2.5" exhausts, then don't bother going with a 3" exhaust. By asking for 3" when the shop wants to build with 2.5", you are asking them to go outside of their normal design envelope and costs will go way up.

This is an OM617, not a 500hp car.

You mention building an exhaust out of pre-bent sections like it's a bad thing. It's not. In fact, it's preferable - especially if it means that you can get stainless.

The shop with the hydraulic pipe expander will build it faster.

Summary: 300-series stainless is worth it. 400-series lasts a lot longer than aluminized steel, but it does surface rust in salty environments (I'm running 400-series stainless). The diameter is almost totally irrelevant. Anything >=2" will do the job just fine.
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  #14  
Old October 6th, 2015, 10:40 PM
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Here the last rough quote I got was ~$500 for a full system and $300 for y-pipe back
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Old October 6th, 2015, 10:41 PM
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12 to 15 hours under UMSW rules. United muffler shop workers union.

2 to 3 hours non Union.

Lmao
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  #16  
Old October 7th, 2015, 08:23 AM
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I did a 2.5" straight pipe and the guy charged me $250. He said that I should paint all the welds to avoid rusting since rust starts at the welds. He doesn't tell this to his customers but I'm a cool white boy according to him. If you come to the DC area I can hook you up. The $250 is cash. Credit cards have a different price

BTW he took less than 2 hours and all the bends are pretty reasonable
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Old October 7th, 2015, 08:52 AM
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Quote:
Originally Posted by ontheway View Post
First quote is in for a 304 stainless exhaust with one flex pipe and two couplers. $600 in parts and 12-15 hours of labor at $100 an hour. This seems exorbitantly high, especially the Amount of hours for this job.

Anyone have a perspective or opinion on this quote?
That's the price of a shop that doesn't want to do the work.
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  #18  
Old October 7th, 2015, 12:11 PM
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Ehhh, I got a custom quad tip exhaust quoted on my S60R, it was a very straight forward job and they quoted around $1300 for non stainless....
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Old October 7th, 2015, 12:21 PM
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Ehhh, I got a custom quad tip exhaust quoted on my S60R, it was a very straight forward job and they quoted around $1300 for non stainless....
99.99999% of the worlds Volvo owners would pony up and ask where the nearest Starbucks is. They had no idea that you are the ONLY Volvo owner on the planet that knows how to use an open end spanner for something other than a napkin weight at an outdoor BBQ.
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Old October 7th, 2015, 01:40 PM
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Where

Quote:
Originally Posted by Tribe View Post
I did a 2.5" straight pipe and the guy charged me $250. He said that I should paint all the welds to avoid rusting since rust starts at the welds. He doesn't tell this to his customers but I'm a cool white boy according to him. If you come to the DC area I can hook you up. The $250 is cash. Credit cards have a different price

BTW he took less than 2 hours and all the bends are pretty reasonable
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Present:
1960 SII 109"- "Red Square"
1984 90 Tdi- "Yamelo"
1988 RRC- "Chewbacca"
1987 RRC- "Chewy 2"
2008 RRS SC- "The Supersofa"

Past:
1959 SII 88"- "The Little Green Beastie" last seen in NY
1972 SIII 88"- "GreenHELL" now in NC
1988 90 "Eric the Half a Bee" half a truck, sold for parts
1991 RRC- never got a name- long since recycled
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