My new 3" exhaust setup on the mini (pics)

[NoDestiny]

Got all my piping, mufflers, etc. from Summit to get going on the 3" exhaust system (nearly turbo-back... still going off a few inches of 2.5" stock downpipe). Got it in Monday, and have only had a few windows of about an hour each to work on this.

I have to use a hacksaw and an Arc welder... so its taking me quite a bit of time I would go get the right saw setup and a new MIG welder... but i'd rather work with what I got right now, especially since the holidays have robbed me of all my money as it is!

Exhaust setup is (in order):
2.5">3" adapter off down pipe
3" Exhaust cutout
3" mandrel bent pipe, 45*
3" catco cat
3", 20" L Dynomax super turbo
3" mandrel bent pipe, 90*
3" side exit pipe (clamped instead of welded, in case of future adjustment needs)


Right out of the box, ready to weld up


After welding comparison to stock


LOL! Stock 2" pipe VS new 3" setup.


This was my best weld w/ the arc welder of the night. Im starting to get the hang of it! ...


...up until I hit a weak spot and put a hole... errr... 4 into it. Got frustrated, went to bent a rod that stuck, and it put a nice little hole in my hand. I screamed... then laughed. Just one of those over the top pull your hair out moments that just turn out to be... dumb.


Painted everything black w/ BBQ paint. Worked well on my neon, why not here? Keeps it protected and stealthy!


Though not complete, here it is. I still need to weld up the actual side exit part as the 3" butt clamp I got was a JOKE. Ah well...

Sound wise? This thing IS NOT LOUD. I could not tell a bit of difference between the loudness of stock VS this. AT ALL. Full boost or not... but on the road, it spools a bit faster... and because the computer doesn't know whats going on yet, it goes into overboost protection (14psi limit) near instantly since it is lost w/o backpressure hahaha

[jory]

Sweet set-up! I do the same thing with all my exhaust work on my cars, painting them black makes it less shiny which is a good thing Can you get a sound clip?

[Gutfeeling]

Haha Sweet! Sound clip is a must!

[NoDestiny]

Lol, sound clip would be pointless... Let everything break in and well see how it sounds then. Right now, it is LITERALLY unheard at any speed or RPM in the cab. New turbo may help...

(...and maybe uncapping the cutout! But I started it without the downpipe connected and it was MUCH quieter than I expected)

Though I do have a nice Sure mic that I use to record my music... would be good quality if I can get it going

also, big problem right now is it keeps hitting over 14psi and hits the overboost. Even after a computer reset! Oh well, im getting my boost controller (TurboXS high performance) tomorrow.

[gerbot_3000]

Please let us know if it works perfectly with the boost controller, i am very interested in going 3" but everybody keeps telling(they are right) that you will hit overboost, but what if YOU use a boost controller!!?? that is what i want to know, I DO have the boost controller but i dont have the 3".. would be nice

[NoDestiny]

Well, something bad happened where Im loosing a ton of oil VERY quickly (dumping out somewhere) so I gotta fix that first. But yeah, watching my wideband O2, it was doing fine at 11:1 AFR till it hit the overboost, then leaned out for a second to 22:1 (Which is basically NO fuel).

A boost controller should fix it, as the stock solenoid is designed to get 10psi with a stock exhaust (but well see what happens!)

[crazymadbastard]

I do not think that a boost controller will solve the over boost condition. The problem is that the tiny mits turbo is too small and will not be able to let enough exhaust be bypassed to control the boost. I pray for your engine. Check your oil feed to your turbo on the pass side along the top of the tranny. It probably was "repaired" at some point with some cheap hose and clamps and now let go.

[GLHNSLHT2]

+1 mitsu's and free flowing exhaust don't mix. Where in Idaho?

[NoDestiny]

Quote:

Originally Posted by crazymadbastard I do not think that a boost controller will solve the over boost condition. The problem is that the tiny mits turbo is too small and will not be able to let enough exhaust be bypassed to control the boost. I pray for your engine. Check your oil feed to your turbo on the pass side along the top of the tranny. It probably was "repaired" at some point with some cheap hose and clamps and now let go.

Hmmm. Well, guess well find out shortly! The reason I figure its the stock controller is because it does the 5lbs with no problem, but once the controller kicks in @ 4K, thats when it creeps to 14+psi. If I ignore the overboost protection, 2nd gear will usually even out at under 14psi, though.

I will check that hose! Seems thats the one everybody is pointing at thus far!

Quote:

Originally Posted by GLHNSLHT2 +1 mitsu's and free flowing exhaust don't mix. Where in Idaho?

Yeah, makes me want a Garrett 10x more!

Im in Payette, which is right next to Ontario, Oregon.

[NoDestiny]

Put on the new boost controller... turned ALL the way down, and STILL overboosting! Gees this is crazy... Looks like I might have to find some type of "restrictor" for my exhaust to make this work... or do the diode on the MAP sensor so it doesn't see overboost and just keep an eye on the wideband.

[Gutfeeling]

Wastegate vacuum hose still attached?

[NoDestiny]

I put new hosing on from the stock controller outlet to the boost controller, then boost controller to the waste gate. boost controller works, went from 5-10 psi right off the line, but always creeps the same. DOH!

[GLHNSLHT2]

what happens if you run just a straight line from the intake to the actuator?

[gerbot_3000]

i am thinking, would a garret behave the same on a 3" exhaust that the mitsu behaves stock?, then you(we) haha should get a garret!

[NoDestiny]

I SHOULD get a garret. As for straight turbo-watergate connection, not sure. Im going to experiment more later. First im going to move the line from the top side of the turbo where the stock controller setup went to just on the end of the snail... see what that does. Then ill bypass the controller all together if that doesn't work.