Step-by-step: Welding a Custom Exhaust System on a Subaru Wrx for Better Thrust and Sound

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Welding a custom exhaust system on a Subaru WRX can significantly enhance both thrust and sound. This guide provides a step-by-step process to help you create an exhaust system tailored to your preferences. Follow these instructions carefully for a successful installation.

Tools and Materials Required

  • Welding machine
  • Welding helmet
  • Protective gloves
  • Angle grinder
  • Exhaust tubing
  • Exhaust hangers
  • Flanges
  • Measuring tape
  • Marker

Before starting, ensure you have all necessary tools and materials. This preparation will make the process smoother and more efficient.

Step 1: Planning the Design

Begin by planning the design of your exhaust system. Consider the following:

  • Type of sound you want to achieve
  • Performance goals (thrust increase, back pressure)
  • Legal regulations regarding noise levels

Sketching your design can help visualize the layout and determine the length of tubing required.

Step 2: Measuring and Cutting Tubing

Accurate measurements are crucial for a well-fitting exhaust system. Follow these steps:

  • Measure the distance from the catalytic converter to the rear of the vehicle.
  • Mark your exhaust tubing accordingly.
  • Use an angle grinder to cut the tubing to the desired lengths.

Ensure that the cuts are straight to facilitate better welding.

Step 3: Preparing the Welding Area

Safety is paramount when welding. Prepare your workspace by:

  • Clearing any flammable materials.
  • Ensuring good ventilation.
  • Setting up your welding machine and tools in an organized manner.

Wear all protective gear, including gloves and a welding helmet, to safeguard against sparks and UV rays.

Step 4: Assembling the Exhaust System

With your tubing cut and workspace prepared, begin assembling the exhaust system:

  • Attach the tubing to the flanges using clamps.
  • Position the exhaust hangers to secure the system in place.
  • Check alignment to ensure proper fitment.

Make any adjustments as necessary before proceeding to the welding stage.

Step 5: Welding the Exhaust System

Now it’s time to weld the exhaust system together:

  • Set your welding machine to the appropriate settings for the material thickness.
  • Begin welding at the flanges, ensuring a strong bond.
  • Weld all joints and connections, moving along the tubing.

Be sure to maintain a steady hand and consistent speed for even welds.

Step 6: Finishing Touches

After welding, inspect all joints for any gaps or weak points. If necessary,:

  • Re-weld any areas that require additional strength.
  • Use an angle grinder to smooth any rough edges.
  • Clean the exhaust system to remove any debris or contaminants.

Finishing touches ensure a polished look and functionality.

Step 7: Installation of the Exhaust System

With the exhaust system fully assembled and finished, it’s time to install it on your Subaru WRX:

  • Lift the vehicle using jack stands for safety.
  • Remove the old exhaust system if necessary.
  • Install the new exhaust system by reversing the removal process.

Ensure all bolts are tightened properly and that the system is securely mounted.

Step 8: Testing the Exhaust System

Once installed, it’s important to test the new exhaust system:

  • Start the engine and listen for any unusual sounds.
  • Check for leaks at all joints and connections.
  • Take the vehicle for a test drive to assess performance and sound.

Ensure everything is functioning as expected before concluding the project.

Conclusion

Welding a custom exhaust system on your Subaru WRX can be a rewarding project that enhances both performance and sound. By following these steps, you can achieve a professional-looking installation that meets your specific needs. Remember to prioritize safety throughout the process, and enjoy the new driving experience!