Exhaust & Fabrications

We custom make and fit all types of exhaust systems to all makes of cars, four wheel drives and small trucks. Whether it be a 3" stainless mandrel bent system for a Subaru WRX or Nissan 200SX to a replacement muffler for a Honda Accord we can do it.

We design, construct and fit intercoolers and piping for forced induction systems. All components are of the highest quality. We carry a large range of stainless sports exhaust components.

 

 

 

Want to find out more information about the exhaust system and its components? Then read on!

What is the exhaust system?

An exhaust system is a complex automotive parts assembly which has a series of functions to perform. It must...

 

What parts make up an exhaust system?

Note: Not all exhaust systems contain all of the following components.

 

The Tailpipe

The tailpipe is a long metal tube attached to the muffler. It sticks out from under the body of your car, at the rear, in order to discharge the exhaust gases from the muffler of your engine into the air outside the car.

The Muffler & Resonator

Exhaust gases leave the engine under extremely high pressure. If these gases escaped directly from the engine the noise would be tremendous. For this reason, the exhaust manifold sends the gases to a muffler where they go through metal plates, or tubes, with a series of holes. The pressure of the gases is reduced when they pass through the muffler so they go out of the tail pipe quietly.

The muffler is made of metal and is located underneath the body of the car. It's connected between the tail pipe and the catalytic converter.

There are two types of muffler design. One type uses several baffled chambers to reduce noise. The other type sends the gases straight through perforated pipe wrapped in metal or fibreglass. This type of muffler is designed for the purpose of reducing back pressure and, consequently, makes slightly more noise.

Since a muffler cannot reduce the noise of the engine by itself, some exhaust systems also have a resonator. Resonators are like little muffler, and are usually the "straight through" type. They are added at the end of the exhaust system to take care of any noise that has made it through the muffler.

The muffler quiets the noise of the exhaust by "muffling" the sound waves created by the opening and closing of the exhaust valves. When an exhaust valve opens, it discharges the burned gases at high pressures into the exhaust pipe, which is at low pressure. This type of action creates sound waves that travel through the flowing gas, moving much faster than the gas itself (up to 1400 m.p.h.), that the muffler must silence. It generally does this by converting the sound wave energy into heat by passing the exhaust gas and its accompanying wave pattern, through perforated chambers of varied sizes. Passing into the perforations and reflectors within the chamber forces the sound waves to dissipate their energy.

The Catalytic Converter


When your engine burns fuel, it produces gases that are bad for the environment. These noxious gases are hydrocarbons, carbon monoxide and nitrogen oxides. To prevent the engine from polluting the environment with these gases, we include a catalytic converter in our emission systems.

The catalytic converter is installed in the exhaust line, between the exhaust manifold and the muffler, and makes use of chemicals that act as a catalyst. A catalyst is a chemical that causes a reaction between other chemicals without being affected itself. In the case of the catalytic converter, the chemicals it contains cause a reaction in the pollutants in the exhaust. The pollutants are changed from harmful gases to harmless ones before they are let into the environment through the tail pipe.

Basically, the harmful gases enter the catalytic converter, a kind of stainless steel container. The converter is lined with chemicals such as aluminium oxide, platinum and palladium. These chemicals cause the carbon monoxide and hydrocarbons to change into water vapour and carbon dioxide. Some converters have a third lining of chemicals, platinum and rhodium, that reduce nitrogen oxides (three-way, dual-bed converter).

The reason that leaded gas cannot be used in an engine with a catalytic converter is that the lead coats the chemicals in the converter. This makes them unable to do the job anymore, since the chemical lining can't come in contact with the pollutants. At first, this was a big disappointment, because lead acted as a lubricant and helped to reduce wear on some of the engine parts. Luckily for our engines and the environment (not to mention us), car manufacturers soon got around the problem by making tougher parts and coating them with special metal.

The Exhaust Manifold and Header

The exhaust manifold, usually constructed of cast iron, is a pipe that conducts the exhaust gases from the combustion chambers to the exhaust pipe. It has smooth curves in it for improving the flow of exhaust.

The exhaust manifold is bolted to the cylinder head, and has entrances for the air that is injected into it. It is usually located under the intake manifold.

A header is a different type of manifold; it is made of separate equal-length tubes and is usually used to increase power output.

Manifold to Exhaust Pipe Gaskets

There are several types of gaskets that connect the exhaust pipe to the manifold. One is a flat surface gasket. Another type uses a ball and socket with springs to maintain pressure. This type allows some flexibility without breakage of the seal or the manifold. A third type is the full ball connector type, which also allows a little flexibility.

Why do exhaust systems wear out?

Many factors can affect the life of an exhaust system:

Result: Deterioration from the inside out. Acid buildup occurs most when the engine and exhaust system don't have a chance to fully warm up.

Does a worn exhaust system affects more than noise? YES

A worn exhaust system will also:

A thorough inspection of the complete exhaust system is necessary to determine the need to replace individual components within the system.