GEE-OTTO Posted November 12, 2009 Share Posted November 12, 2009 Well well the months have passed and I have went through a few exhaust setup possibilities on my 08 Legacy 2.5i. While they all would work the one thing that I really wanted to develop an idea that is 100 percent bolt on for us 06 and newer guys. I had a EJ20G manifold that I chopped up and it worked okay and I sold that to an impreza owner then I had a set of Borla reps which I used a 05 RS mid pipe to connect that to my stock axleback. That worked fine as well but recently I picked up a Stock EL manifold that was in mint condition for very cheap compared to the $500+ from Subaru. I know I had been talking and talking about this for months literally but finally I got it accomplished. Lets start with the project piece a 2007 Subaru EL manifold: http://i144.photobucket.com/albums/r182/GEE-OTTO/hdr1.jpg Very nice i will admit. I clamped it down to keep the distances true while working on the piece. I recommend doing this to anybody that attemps this similar mod. So I removed all the heat shielding and fiberglass packing ( which I think helps in tww ways one with heat and second with noise from the exhaust pulses. Another interesting thing I found was that this EL isnt exactly equal in length all the way around the two passenger side primaries are 24 inches long the two driver side ones are 19 and 22 inches long stock. http://i144.photobucket.com/albums/r182/GEE-OTTO/Modifications/hdr6.jpg To start I put a relief cut in the number 4 primary near the collector with a cutting wheel. I then cut the primary directly past the expansion joint. After I made my cuts I used a torch to heat the pipe near the relief cut and while it was super hot i pulled the primary so that it lined up with the number 1 primary. http://i144.photobucket.com/albums/r182/GEE-OTTO/Modifications/hdr7.jpg http://i144.photobucket.com/albums/r182/GEE-OTTO/Modifications/hdr9.jpg Once I got it lined up where I wanted it I then welded a 90 degree piece to the new location of the stock expansion joint and then had to fabb a piece to fill in that gap http://i144.photobucket.com/albums/r182/GEE-OTTO/Modifications/hdr12.jpg http://i144.photobucket.com/albums/r182/GEE-OTTO/Modifications/hdr11.jpg After I got the right angle ( I needed a 34 degree angle so I cut two 17's on each side of joint) i trimmed a piece and welded that to fill in the gap. http://i144.photobucket.com/albums/r182/GEE-OTTO/Modifications/hdr13.jpg After i cleaned up the welds i painted the mild steel part with rust-o-leum 2000 degree paint to keep it from rusting. I didnt need to paint the rest for two reason 1. i used stainless welding wire to reweld the existing stainless tubing 2. I am going to wrap the piece in thermo wrap once it is to my liking. The end result is this piece : http://i144.photobucket.com/albums/r182/GEE-OTTO/Modifications/hdr14.jpg http://i144.photobucket.com/albums/r182/GEE-OTTO/Modifications/hdr15.jpg The most difficult about this mod is finding a spare 06 Plus manifold it took me 5 months Not to bad if I may say so Once I get it fitted to my car ( this weekend) I give an update. So there you have it so far and to all the turbo guys WE ( N/A people) understand this purpose of this project so spare us the bs remarks Link to comment Share on other sites More sharing options...
rlee429 Posted November 12, 2009 Share Posted November 12, 2009 welding looks so fun =) GL on the project. Link to comment Share on other sites More sharing options...
OhBe1 Posted November 12, 2009 Share Posted November 12, 2009 What are your expectations from this effort? 06LOB2.5i MT, JDMRSB, GYTTs, HPS, LGT Mufflers & Leather Wheel, SubiMomo Knob, Inalfa Moonroof, Clutch Switch Bypass, DeDRLd, DeChimed, & Straight Headrest. Link to comment Share on other sites More sharing options...
GEE-OTTO Posted November 12, 2009 Author Share Posted November 12, 2009 What are your expectations from this effort? Well i was always told dont say something if you don't plan to do it No actually the reason behind this little project was a couple of reason 1 ppl always talk about doing out of the box things in the NA crowd and never do esp when it comes to exhausts. I had been debating this for a long time and once i got my hands on a spare manifold i leapt. Second this couls be the base for a completly BOLT ON UEL for us 06+ guys that want it not much more than that.... oh and i like to weld and cut and be manly Link to comment Share on other sites More sharing options...
katalyst Posted November 12, 2009 Share Posted November 12, 2009 props in for some sound clips. looks like it was pretty fun putting this together Link to comment Share on other sites More sharing options...
CasopoliS Posted November 12, 2009 Share Posted November 12, 2009 fun project... you just messed up how the pulses merge but I guess its not that important. Link to comment Share on other sites More sharing options...
GEE-OTTO Posted November 12, 2009 Author Share Posted November 12, 2009 fun project... you just messed up how the pulses merge but I guess its not that important. In case you missed the overall gist of the project that was the point:lol: The EL has all the cylinders in phase so you don't get any rumble this should hopefully throw cly 4 out of phase and create some nice tones Link to comment Share on other sites More sharing options...
OhBe1 Posted November 12, 2009 Share Posted November 12, 2009 So, for sound only, then (besides the fact that you can, of course)? 06LOB2.5i MT, JDMRSB, GYTTs, HPS, LGT Mufflers & Leather Wheel, SubiMomo Knob, Inalfa Moonroof, Clutch Switch Bypass, DeDRLd, DeChimed, & Straight Headrest. Link to comment Share on other sites More sharing options...
GEE-OTTO Posted November 12, 2009 Author Share Posted November 12, 2009 So, for sound only, then (besides the fact that you can, of course)? That to! But you know youve read countless posts about 06 plus guys not having anything bolt on as far as this goes so i wanted to show them that it can be done and it isn't that hard. It is no secret that many subbie owner want that rumble that why Borla made single and Dual port UEL headers for the 05 and older crow, they just stopped in 06 b/c subaru switched to the integrated catalytic converter/manifold design and i guess it was too expensive to R&D a UEl for these models Link to comment Share on other sites More sharing options...
burnout8488 Posted November 12, 2009 Share Posted November 12, 2009 I like you. Link to comment Share on other sites More sharing options...
GEE-OTTO Posted November 12, 2009 Author Share Posted November 12, 2009 I like you. Link to comment Share on other sites More sharing options...
shtbxr22 Posted November 15, 2009 Share Posted November 15, 2009 no, no, no. this is not right. Link to comment Share on other sites More sharing options...
shtbxr22 Posted November 15, 2009 Share Posted November 15, 2009 you're not done yet...... Link to comment Share on other sites More sharing options...
GEE-OTTO Posted November 16, 2009 Author Share Posted November 16, 2009 you're not done yet...... Why not I have a UEL bolt on manifold for a 06+ N/A subaru no wire cutting, pipe destruction etc Oh wait you want me to slap that Ej20G manifold back one Link to comment Share on other sites More sharing options...
GEE-OTTO Posted November 16, 2009 Author Share Posted November 16, 2009 You are right I have to shorten another primary the number 2 Link to comment Share on other sites More sharing options...
NORULZleggy Posted November 16, 2009 Share Posted November 16, 2009 GEE you going to hit a dyno when you get these on? Link to comment Share on other sites More sharing options...
GEE-OTTO Posted November 16, 2009 Author Share Posted November 16, 2009 GEE you going to hit a dyno when you get these on? They are on already I wont spend the money for a dyno for a 2.5i unless i put a turbo or SC on it you really dont need to know if you gained 10 hp or not its not like you can feel it one Link to comment Share on other sites More sharing options...
shtbxr22 Posted November 16, 2009 Share Posted November 16, 2009 you have to considerably shorten cylinder #'s 1 and 3. this is what causes the burble. look at a turbo manifold and notice how much longer #'s 2 and 4 are. Link to comment Share on other sites More sharing options...
GEE-OTTO Posted November 17, 2009 Author Share Posted November 17, 2009 you have to considerably shorten cylinder #'s 1 and 3. this is what causes the burble. look at a turbo manifold and notice how much longer #'s 2 and 4 are. Yeah I if you look at the picture i plan to shorten #1 by about 6 inches ( chop out all the bends put in straight 90 degree running back to the collector. and make number 3 the same way. Link to comment Share on other sites More sharing options...
shtbxr22 Posted November 17, 2009 Share Posted November 17, 2009 excellent! post complete pics please. Link to comment Share on other sites More sharing options...
GEE-OTTO Posted May 25, 2010 Author Share Posted May 25, 2010 ive got some more pics coming on this topic Link to comment Share on other sites More sharing options...
shtbxr22 Posted May 25, 2010 Share Posted May 25, 2010 Link to comment Share on other sites More sharing options...
stinolan Posted September 12, 2012 Share Posted September 12, 2012 You are right I have to shorten another primary the number 2 Alright first sorry to bring this post back this is what i wanted to see... cuz im cheap and dont have the time to search for the proper rs uel and then cut it up. Ok are there anymore pics or info on this project? Or did you ever finish this one? How id it sound with just that one side cut and refabed? Could this be completely done in one day and with a cheap harbor freight wire welder? Any extra info pics or tips would be awesome Thanks Link to comment Share on other sites More sharing options...
Haight 05LGT Posted September 12, 2012 Share Posted September 12, 2012 Subscribe =). Also in for some sound clips. Link to comment Share on other sites More sharing options...
GEE-OTTO Posted September 14, 2012 Author Share Posted September 14, 2012 Alright first sorry to bring this post back this is what i wanted to see... cuz im cheap and dont have the time to search for the proper rs uel and then cut it up. Ok are there anymore pics or info on this project? Or did you ever finish this one? How id it sound with just that one side cut and refabed? Could this be completely done in one day and with a cheap harbor freight wire welder? Any extra info pics or tips would be awesome Thanks I went to a LGT stock manifold modified to fit on my 2.5i, my modified stock manifold went to AVO Link to comment Share on other sites More sharing options...
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