I dont get why it costs so much to build.. you can get megaphones like that made from any number of exhaust shops for pretty cheap.


Just one example I found on a quick google search.
http://www.speedwaymotors.com/Plain-...Inch,1719.html


If you are running a very short exhaust its good to have a reverse cone at the end of the megaphone as well.. like this piece.

 

Wanted to give you kudos for making your own part. Will keep following the progress.

 

I'm sure there are probably some suppliers that would be somewhat cheaper than what I've found, but I don't think the link you provided would necessarily be one of them. The cost of a stainless steel megaphone is considerably more than mild steel, and the cost goes up exponentially with size. My mid-pipe requires 4 stainless steel cones, one of which is a custom perforated cone. The custom cone adds a lot of cost, since production cost is inversely related to quantity.

 

I can understand your questioning, but if you consider the time that has been taken to marry a HFC with a expansion chamber that performs well and FITS in a S2k, the price is decent. From my understanding this mid-pipe should be 49-state legal as well.

 

Burns stainless has stainless 2 to 4 inch megaphones for under $50.

Bunger.. we build exhausts that incorporate megaphones for various cars all the time. It's been proven to provide major gains in nearly every application, they dont cost $1000, and IMHO whoever is charging the OP that much to build this is ripping him off if what he says is true! One thing I hate more than anything is seeing someone being ripped off.

 

I'm not sure what you're getting at, but you are only considering 1 part required to build the mid-pipe (in the wrong size). If you're going to use Burns Stainless for price comparisons, then you would need a megaphone muffler ($400, but not available in the right size). a 4" bend ($105), 2 V-bands ($170), and a reducer cone ($40). Then you would also need to buy something like an Invidia test pipe ($80) and a Magnaflow HFC ($100+). The total for those parts winds up at $900 if you don't include shipping. Then you need to go find a shop that will build the thing, which will have a very wide range of cost estimates. The best quote I received for doing all the cutting and welding using the parts I provided was $800 per unit. Of course, this would be in addition to the cost required for them to build the jigs.

Fabricating my mid-pipe is a VERY time consuming process, due to the precision required for each cut (compound miter cuts). A perfect mid-pipe will only have about 1/4" gap between the top of the expansion chamber and the bottom of the car. It will also have about 1/4" gap between the 2nd V-band clamp and the lower tie bar, and about 1/2" gap between the top of the same V-band clamp and the inner CV joint on the passenger side. The slightest error in the assembly will result in a pipe that rubs or rattles against something. It takes me more than 8 hours to build 1 unit (tack welded only), since most of the cuts have to be re-cut or adjusted with a belt sander or grinder to get the fitment right.

 

Did you see that my mid-pipe is NOT just a hollow chamber?

 

gernby ftw! when are these babies gonna be ready? would these smell like some test pipes do? i know the best mod for an 08 is a test pipe, but i dont want those things because of the smell and pollution. i was thinking of a HFC but i think this will be a better, but pricey, option.

 

I don't know why it took me so long to really catch the full irritation of this post, but I don't know of ANY megaphone applications for 49 state street legal cars that are pleasant on the highway. Please provide some links! Maybe my patent application should be rejected.

 

answered my own question with a litte search lol