Having finalized the dimensions for my kit car exhaust system, my next step was to procure the necessary materials. I visited my regular supplier of tubing for blower manifolds and inquired about perforated tubing. Fortunately, they had some in stock, which was ideal for my project. Alongside the perforated tube, I also acquired the mandrel bends and flanges essential for constructing the exhaust headers.
My primary reason for seeking perforated tubing is to fabricate custom silencers, or mufflers as they are commonly known in the US. The market lacks readily available silencers that are compact enough for my kit car. Therefore, creating them from scratch is the only viable solution. This approach, while more involved, offers the advantage of tailoring the exhaust system for a precise fit. Achieving ‘perfection’ in such custom builds is always a balancing act, but my main concerns revolve around ensuring adequate ground clearance and managing the limited space between the rear valence and the engine bay.
The design for these custom silencers will mirror the twin parallel straight-through tube configuration found in Carrera exhausts. While I am hopeful that this design will yield an acceptable noise level, I am also aware that many builders often incorporate an additional silencer at the exhaust tip. This suggests that my initial optimism about noise levels might be somewhat misplaced.
With all the necessary components now in hand, the fabrication process can commence. I plan to begin with the 4-into-1 collector assembly. Following this, I will move on to constructing the mufflers, although the packing material will be added later. Final assembly of the complete exhaust system will be deferred until I have fitted the rear bumper. I was fortunate enough to find a steel rear bumper that matches the front of the car, and I intend to wait until it is mounted. This will allow me to position the exhaust tip precisely where I want it, tucked neatly underneath the bumper for a clean and integrated look.
