Flatt Racing Exhaust Replica
 

I was recently contracted to build a new exhaust system for Chuckles. He had purchased two Thrush mufflers in hopes to make a Flatt Racing exhaust replica.. This is how it came out:)

http://i65.photobucket.com/albums/h2...X/DSCF1250.jpg

http://i65.photobucket.com/albums/h2...X/DSCF1255.jpg

http://i65.photobucket.com/albums/h2...X/DSCF1249.jpg

http://i65.photobucket.com/albums/h2...X/DSCF1247.jpg

Still waiting for the tips to arrive... I am about to fire it up to see how she sounds:D

Tom

Re: Flatt Racing Exhaust Replica
 

Give us sound!! ::D:D (Pretty please?)

Re: Flatt Racing Exhaust Replica
 

It sounds great!!! One last pic because I didn't get this angle...

http://i65.photobucket.com/albums/h2...X/DSCF1256.jpg

I cannot get sound on my camera for some reason:confused:

Tom

Re: Flatt Racing Exhaust Replica
 

That looks awesome. It looks like minimal work to make too, relatively strait with low resistance. Is this something you're considering adding to your "bolt on and go" things for sale, or is this a once and done thing?

Re: Flatt Racing Exhaust Replica
 

Not that simple. I had to make the Y at the mufflers which took about 2hrs by itself. We are considering making bolt-on exhaust systems but they will use a polished stainless bullet muffler like this one...

http://simplepic.net/albums/userpics...l_DSCF1087.JPG


Tom

Re: Flatt Racing Exhaust Replica
 

Please provide a sound clip! I am dieing to here what it sounds like

Re: Flatt Racing Exhaust Replica
 

As soon as I can get another camera in here to record it... Mine doesn't do sound

Tom

Re: Flatt Racing Exhaust Replica
 

I will do video on Saturday. Looks great! I'm excited about this one.

Re: Flatt Racing Exhaust Replica
 

Looks sweet. That's very similar to the design I have for the exhaust I'm going to make. I have a pipe bender at work which does near mandrel-quality bends, so I can make all of the pipes a single piece. What are the dimensions of the mufflers you used at the rear? I had planned on some Borla ones that look to fit the bill pretty well.

Re: Flatt Racing Exhaust Replica
 

I like hte first one you posted better. Keep at it!

Re: Flatt Racing Exhaust Replica
 

System particulars...

2" pipes post pre-cats
Dual 2" in single 2.5" ot magnaflow cat
2.5 Resonator (not sure of brand, customer supplied it)
Custom 2.5 inlet 2" dual outlet y pipe
2 2" center in offset 2" outlet mufflers
going to dual slant oval tips.

100% mandrel bent with 4 hangers and single 3bolt flange after main cat

Tom

Re: Flatt Racing Exhaust Replica
 

Well I test drove the car last night and this morning... So some feedback on the system

It is quite tame, not loud, obnoxious, or tinny. It has a nice low end growl that feeds to a nice top end light roar. This car has a cone filter in the engine bay... I know, I know... and the intake it louder than the exhaust is. I am very glad with how the system came out and how good it sounds. It is close to the Stebro sound just a bit quieter:)

Tom

Re: Flatt Racing Exhaust Replica
 

Tom, now would this system be a performance upgrade, meaning more efficient (less restrictive), as compared to the Stebro system? All I need is the sound clip, I'll most likely be sold on this setup. Was this a one off type deal, or would you be willing to do this again?

Re: Flatt Racing Exhaust Replica
 

would think this system does flow better than the stebro... But I would rather use a straight through muffler instead of the chambered mufflers that he had brought here. Also If you wanted a performance exhaust, getting rid of the pre-cats would be needed. The system would need to be bigger too, I would say 2.25 head pipes... 3" cat back to 2.25" tails...

Oh did I mention equal length headers??... More or less, someone looking to replace the exhaust w/ new components and wants a little more sound, this is ideal... If you want a real performance exhaust, thats a totally different story.

I would not be opposed to making a similar system again though

Tom

Re: Flatt Racing Exhaust Replica
 

We will be making bolt-in exhaust kits soon. Here is a pic of the components we will use.

http://i65.photobucket.com/albums/h2...X/DSCF1258.jpg

They will look like the exhaust on the black car mentioned above except a little different for the bolt-in-ability

Tom

Re: Flatt Racing Exhaust Replica
 

I am loading video right now of two systems side by side. Both are brand new.

The car on the left has our Bullet cat-back with a 2-1 magnaflow cat(still needs tips)
The car on the right is the one pictured above which is the Flatt Replica.

The flatt exhaust is not as raspy as it sounds in the video... It is quite nice so take the video with a grain of salt



Tom

Re: Flatt Racing Exhaust Replica
 

I've made my choice.. lol

Re: Flatt Racing Exhaust Replica
 

Me likey the bullet muffler :D

Re: Flatt Racing Exhaust Replica
 

how much are you looking to sell your kit for tom?

I would be interested in 5 months once I am back from Germany...Will you have them by then?

Re: Flatt Racing Exhaust Replica
 

We are making our first bolt-in cat-back tonight. We will post pics and videos when it is completed. They will be available as soon as we deem it a success

Tom

I think the Flatt replica actually sounds really cool.

Re: Flatt Racing Exhaust Replica
 

I really like the replica too, I do like the low tone of the bullet personally but the Flatt-rep really has a nice unique sound that really isn't captured well in the video

Tom

Re: Flatt Racing Exhaust Replica
 

I like it too. Ballsy, but not overdone.

Re: Flatt Racing Exhaust Replica
 

I love the one on the left.

Re: Flatt Racing Exhaust Replica
 

got the bolt-in cat-back done today... Loading pics and making a new thread

Tom

Re: Flatt Racing Exhaust Replica
 

I saw the video before I heard the car, and I'm so glad it doesn't sound like that.:D The car has a very mellow tone, and I am extremely happy with the result. Tom did a great job!:cool:

Side note: What is wrong with my air filter? seriously guys, educate me, what did I do wrong with that?:o (ANSWERED)

Thank you for the above clarification... I always assumed since most show cars have them mounted there, that must be the right spot. I was going to redo the entire intake anyway, so thanks for the knowledge.

Re: Flatt Racing Exhaust Replica
 

Cone filter in the engine bay = warm air intake. Sort of a de-performance mod.

Re: Flatt Racing Exhaust Replica
 

^^^What he said. The whole point of a "performance" air intake is to pull low restriction, cold air into the engine. Cold air is more dense, therefore you get a bit more power. Air under the hood is hot, mainly because of that big hunk of aluminum that makes all the noise. Drawing in the hot air from the engine bay not only robs you of power, it also makes your engine more prone to knock (if you're trying to drive the wheels off it) by bringing in a hotter air charge. Mainly with a cone filter you get more noise, and to many people noise = power, so :banana: [/hijack]

Back on topic, with the Flatt replica being solidly welded/bolted together, is there any concern about stress on the system from the engine twisting under load? The stock exhaust has the sprung flanges into and out of the main cat, giving it some room to flex. I know our engines aren't exactly jumping around the engine bay, but would you be concerned about long term problems? Stress cracking at the welds, etc?

Re: Flatt Racing Exhaust Replica
 

I have access to a digital video camera, I can provide a DVD quality video with sound, just mail me an exhaust setup and I'll put it on my car and send you a video. :D

Re: Flatt Racing Exhaust Replica
 

I have done several systems without flex-joints without issue. more or less as long as it is hung properly, the hangers take all the stress. His system is hung from front to back using... Head bolts, Rear trans hanger, resonator hanger, two tail pipe hangers. Using this, the front of the system is suspended attached to the engine/trans (the things that move) so there is literally no stress there. the othe hangers are rubber so they will flex and move the little bit that the exhaust does move back there.

Tom