2 pipe conversion

personally i'd leave the rear down pipe in place and mod the collector to fit it ,so it would need shortening and sleeving then just get the flanges changes on the front pipe

dave65 wrote: I'n looking at hangers in evilbay at the moment,£85 for a pair bit of a rip off. I like the idea of leaving the rear downpipe in place but how do you resleeve the other bit.

it's needs shortening in height and then a smaller diameter pipe to sleev down diameter and welded in

Done a bit of work on the conversion this afternoon, cut the 4 bolt flange off and the 3 bolt flange off the caponord and got it offered up.

As you can see it will need a bit more trimming so it will line up and its touching the back of the rad at the moment.

At the back end i haf to trim the pipe on the collector, may need a bit more yet but somewhere near. Then a it will need a sleeve welding on as i'm leaving the original rear downpipe in place.

There's a little probe in this collector as you can see in the pic, what is it? and can the wires be cut off.
Anyway my new R&G hangers came yesterday so temporarily put them on and got the end cans in place to see what it would look like.


I'll update when i get a bit more done.

You might need to give the fitting a bit of a heat with a blow torch to be able to slacken the sensor  - they can be mega tight.

or grind off the fitting and get a small plate welded over it

dave65 wrote: Where can i get a blanking plug from.

Azz wrote: The rear header from 04+ fits perfectly (tested on falco couple days ago). Of course with changed flange - the rest need to be modded on Falco.

different swingarm apse on a falco you have it easy

you wont get them perfect on a gen1 due to the engine being slightly offset in a gen2 so one can will sit out more than the other apprently

Hey looking good, get a blog posted up once you've finished!

Good stuff can't wait to see them finished.;)

Got the welding done today off a local lad (Teesside).
Won't get to try it in till next week though as going to Edinburgh for the weekend.

YYeah very nice job looking forward to see them finished & the video of the sound

Forgot to mention I had to drill out the pop rivet on the exhaust can strap and move the strap along about an inch.
The left side can does stand off the swinging arm a little bit more than the right side but a bit of brut force sorted that issue.
The cans looked a bit twisted. I got over this by grinding the locating slot a bit wider on the downpipe.

Nice job

The cans will always sit odd on a gen 1 as the gen2 engine is offset by 5mm hence one side sits out further.

did you cut where the gen2 changed to round tubing and cut through the weld. If so another 5mm off the gen1 flange would have made the difference for clearance...but I think leaving the rear pipe in place is the way to go as I said a while back...so much easier as the gen2 rear down pipe is too tight through the swingarm.

Bodywork...It will need cutting chain side that's for sure you'll have to remove that side can and cut the bellypan..that's going to be the awkward bit.

Removed lamda sensor and blanked off.