New CV boot.....and exhaust

Well, having had the car for a bit over a month now...had a problem. Somehow, i tore the passenger side inner CV boot. Lucky i was going to take the car down to build an exhaust, and noticed it when i was measuring exhaust dimensions. There are a bunch of good threads on changing the boots, so i won't go into too much depth. However, i did find that the porsche 930 boot DID fit, without a problem. so...i took a couple pictures to document the process:

First one shows all the suspension disconnected from the hub. I decided the best way to do the repair was to remove the entire axle and hub, with brake rotor still attached. Also removed the primary cat's, so i could maneuver the axle around.

Second one shows the axle on the ground with the torn boot. the good news is that it must've torn on my last drive, because all the grease was still in there....and then on my clothes...and arms... the recommendation to wear nitrile gloves is a good one! at least my hands were clean at the end of the nights.

I repacked it with some CV lube, re-assembled (3rd picture), put some boot clamps on it, taped it up so i wouldn't damage it on the way back in (4th pic).... and got everything back together.

5th pic....who knew that they had prancing horses even on the bolts?! Made me laugh as i was taking it apart.

...to be continued below
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So the other part of this order was making an exhaust. I've always loved the sound of straight pipes...but wanted something civil enough to drive around town when i'm not trying to alert everyone within a 5 mile radius. So, i decided to make it fully straight when the bypass is open (no cats, no resonators, nothing ). When it's routed through the primary pipes, i wanted to keep the hyperflows it had on (hoping for at least a little muffling), and keep the more restrictive size pipe (2.25" for primary vs 2.5" for bypass). If all else failed, and it was too loud around town, i figured i could fab up some sort of muffler, and make it similar to the ms racing style exhausts. So...the second phase began:

First pic is with the muffler in place, but everything else removed...ready to take out. I did have to remove the bumper to take the muffler out...so you'll see the tape on it in later pictures.

With the muffler out (pics 2 and 3), i could truly see what i was working with. that thing is heavy! I decided to use the flanges from the stock muffler, and tig them to my stainless pipes.

Pic 4 shows the bypass exit, with my Y tig-ed to the flange. The cheap-o china freight tig seemed to do alright...though i definitely missed having a foot control.

Pic 5 shows the bypass system complete.

Pic 6 shows the lower primary flange welded to it's pipe.

Pic 7 shoes everything in place.....almost done!

Pic 8 shows me lining things....which are not quite lined up there. I'm debating cutting the pipes back and buying some tips for it. Thoughts? Idea's where to buy some good looking tips?

And finally...before everyone asks...yes i do have video A buddy of mine made it. It's filmed from his evo- and you'll be able to hear my car over his...no problem.

http://www.youtube.com/watch?v=wLzRF1EEAQA

The best thing of all is that...yes, it's...somewhat loud when cruising. But it's not obnoxious or obtrusive. It's something that i plan on driving on trips with, and i don't think there will be much of a problem with it. However, when you open it up...be prepared to be bathed in noise! It sounds like i could've dreamed about. THIS is why i bought the car. Sure there are faster cars, better handling cars, cheaper more reliable cars....but nothing at all provides the experience like this. Driving it through the mountains today, hearing the echos off of the walls...the sounds under overpasses... it's just amazing. I might have to drive it only on nice days now....because i can't see myself driving with the windows up ever again!

To me, working on the car is half the fun of owning it (otherwise i wouldn't be driving an italian). There are a bunch more projects i'd like to do...including air boxes, diffusers, and anything else i can think of making better...or more personal. Now i'm off....to watch the video again.....and again....

 

pics...
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Frank-
From some of the other threads, the folks on here use this porsche 930 boot on 348's quite often. I don't have exact OD/ID measurements (didn't take them), but i figured i would give it a shot- as the more 'aerodynamic race boot' others use was sold out with no idea when there would be more stock when i bought it. The ID that slid onto the axle was slightly tight, though i had no problem sliding it onto the shaft with some grease on the shaft and boot itself. The ID that slid onto the CV cover was a comfortable fit.


Terry- they're 295/35's