Exhaust flange - Engineering Design Challenge for you Audifans tinkerers
audi at humanspeakers.com
Thu Aug 17 19:29:15 EDT 2006
> I just want a flange. There is nothing wrong with the downpipe flare. That
> ole stainless steel downpipe is still A-OK.
If the downpipe flare is good, the one on the flange is not important.
Just get some 1/4" or 3/8" steel (or stainless) to work with. Make two
squares that are big enough (why two? you'll see...).
Using a good hole saw (Lenox type, eg), cut the correct diameter hole in
Then cut each one - not quite in half, but off-centered enough to allow
for the kerf.
Now take the two slightly larger halves, which will make a perfect
circle put together, and drill the corner holes.
Wrap them around your downpipe and weld them together (bring all three
parts to a real welder, they'll have s/s rod to work with. Make their
job easier by grinding angles at the weld edges for them to fill).
grind off any excess weld.
If welding is not an option, use at least 3/8" stock to start with, and
drill holes in each half, one to pass a bolt and the other to tap for
the bolt. Assemble with two bolts. If the bolts would interfere with
your hole pattern, rotate the hole pattern 20-30 degrees.
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