Replacement Exhaust, Custom made exhaust for Pinin Options

[jezisvole]

Hiya

I have a Shogun/Pajero Pinin 2.0ltr GDI which after 5 years is starting to have exhaust problems. Mitsubishi want £430 + fitting for a new one. ......... BUT CHEAPER doing it ourselves??

What would happen if I/someone else used to welding exhaust, custom made a new exhaust using replacement silencers sized as near as possible to the original, and bought stock exhaust pipe by the metre?

• We have access to a pipe bender, welding equip, and replacement parts (silencers/pipe).
• Universal silencers approx £45 each and 54/2mm exhaust pipe £2.50 a metre !!
• Route of new exhaust to roughly match the stock.
• Sensor holders will be welded to the exhaust pipe (as per orig locations)
• Universal flexi pipe can be bought easily.
• Construction as per stock, ... (From engine block -> bend -> sensor -> flexi pipe -> catalytic converter (to be re-used) -> sensor -> small silencer -> length of pipe up and over -> rear silencer -> tailpipe.

1) Would there be any major problems with this ?
2) Would it be a problem to substitute the 54mm diam/2mm thick stock exhaust for the common 45mm/2mm universal size used by most cars?? (Reason is to increase our chance of getting both replacement silencers as close in size to the original 2 silencers... 1 small after cat, 1 large before tailpipe.)

If this would be possible, then financially it would make huge difference, ....as work-time and equipment is not a problem as we have what we need and plenty of time.

Cheers
Phil

[KiT TeUnG 2549]

Yur exhaust is rusted in many spots?

No i have roworked many exhaust systems , the primary thing is the placement of the downstream sensor and its placment after the catalytic convertor. But it sounds like yu have a pretty great planned out so far and it should work just fine . I would go for it.

Altho id try to stay as close to stock piping size as possible , a little over the factory diameter is fine , but under is not a good idea, all depending , i have seen dual conversions where there were dual piping and the pipes were each smaller than the factory single , which is acceptable. But a single that is smaller than teh upstream piping to the flex pipe onward would cause restriction

[jezisvole]

Hi

It's been a few months since the exhaust problem.
Here's what I did.

The CAT and BOTH silencers were almost like new, no rust, nothing, and anyone who knows the Pinin, knows that the back exhaust box is a monster. (probably why it's so expensive!)
Anyway, both silencers were cut at the weld and reused after a cleaning up. New flanges were bought for the CAT connection and a new sensor holder was bought too.
3m of pipe (2mm) cost about £15 and 45° elbows (2mm) were about a £1 each - which were cut to the correct angle and used for a smooth bend in pipe.

I personally spent 4 days in dismantling, measuring and tack welding the new pipe, which was later OXY welded for good smooth welds.
The whole thing was cleaned, anti-rust sprayed, and coated with exhaust paint, then refitted perfectly and sensor re-attached.

Since then, NO probs and all, car drives fine and quietly.... total cost around £30 incl. accessories. + 2 weekends' work.

STRANGE how the old pipe was TOTALLY rusted to pieces in many places, however the silencers were immaculate !!

I'll post photos if anyone is interested, but they'll be taken after the winter - lots of snow now here.

Cheers
Phil

[KiT TeUnG 2549]

Awsum job , i knew yu could , so yu went thru around same size original pipe? Well thats good , well yu see the exhaust piping most cases a single walled stainless , where as the resonator and silencers are made of a diff material. Sumthin similar to an aluminum blend alloy so it doesnt rust.