Teardrop Side Exit Exhaust

Starting with a 3″ diameter 6″ radius mandrel bend (180 deg) of exhaust tubing, this download shows you the proper place to slice the U-bend with a bandsaw, yielding two really sweet teardrop shaped exhaust tips.  Also included are DXF files for two shapes of laser cut bezels (symmetrical and upswept), plus a plasma template that is clamped into place and used to guide your hand-held plasma around in making the perfect size cutout for the bezels.  It’s not difficult to do – if you have basic fab skillz, you can do it!  Just buy a mandrel bend, slice it as shown, have the bezel parts laser or plasma cut, cut the opening in the body in the desired location, use a bezel to mark where the screw holes go, drill holes, and assemble.  It helps to make some small angle pieces that weld to the exhaust tips and use a few of the screws on the inside of the hole to keep things centered.  10-32 button head or pan head screws work really well.

Please respect the time and effort I put into designing and prototyping this item by not sharing it around willy-nilly.  This is for your own use, and feel free to make as many as you want for your rusty old projects in any quantity, but you buddies will need to buy their own 😉