If at first you don't know how, do it anyway!
Warning. Before reading this and checking out my pictures, let me say that when I started working on my exhaust a long time ago, I didn't know how to weld. This was my first welding project and I learned as I went. I already have plans on building a new exhaust system for my car in the future with much better welds. Enjoy!
So after installing my exhaust I kept all the scarp pipe. I figured I would be able to use it for something later. Of course I have since learned that a cross over pipe (both x and h) add horse power and even out the exhaust. Plus it just plain old sounds cool!
I didn't have one length of pipe that was long enough to work so I decided I could use two pieces and it might actually be easier.
I didn't have one length of pipe that was long enough to work so I decided I could use two pieces and it might actually be easier.
Trial fit
Then I did some trial fits. I used my grinding wheel to notch out what ever was needed to get a decent fit. It didn't need to be perfect for this project.
Mark the fit
Once I had things fitting the way I wanted I marked the drivers side exhaust tube. I traced a circle around the tube once I had it where I wanted it. There is some discussions as to where to put the cross over pipe but honestly I just found a spot that wouldn't cause any room issues.
Find the length
Now that had my locations marked, I wanted to make sure that the cross over pipe was the perfect length. I took the first length and held it in place on the drivers side pipe. Then I put the second length up against the passenger side pipe behind and against the 'in place' cross over pipe. This allowed me to mark/trace the length up against the longer piece of pipe. Then I cut the length with my side cutter. One last trial fit and it looks good. So far so good.
Drilling the hole
Now with everything fitting and ready to weld in, I need to cut the hole. I started by drilling it out as big as I could. Then I used a grinding stone to enlarge it. I didn't want to go to big so I would check the size from time to time.
Putting it together
Now I am ready. I welded my two lengths of H pipe together. That was easy. Then I put it in place under the car. Keep in mind that I still have my exhaust bolted to the car. I put the cross over in place and with my trusty welder I tacked it in place. Now I have only 8 nuts total to undue and my exhaust will come down. I also don't have any tail pipes so it is very easy to drop the exhaust. With things nicely tacked in place I dropped the exhaust and welded things up.
Don't look at the welds
Everything is nice and strong. Even the ugly welds. Don't worry, I plan on coming back to this project in the future and redoing it all. I want to add some cut outs and I figure that I will redo all of it. Also I should mention that my 'tacks' that I thought would hold, well one didn't. So I had to line it up and I was off some. This caused a little bit of a difficult fit when I put the exhaust back under the car. Still I am very happy with it over all. And it cost me some time and scrap material. Oh, and best of all it sounds great while it provides some extra go!
Cost = $free
Cost = $free