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-   -   Stock 08 EL Manifold Modified to UEL!!!!! (http://legacygt.com/forums/showthread.php?t=124863)

GEE-OTTO 11-11-2009 07:30 PM

Stock 08 EL Manifold Modified to UEL!!!!!
 
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/r...-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/r...tions/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/r...tions/hdr7.jpg
http://i144.photobucket.com/albums/r...tions/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/r...ions/hdr12.jpg
http://i144.photobucket.com/albums/r...ions/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/r...ions/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/r...ions/hdr14.jpg
http://i144.photobucket.com/albums/r...ions/hdr15.jpg


The most difficult about this mod is finding a spare 06 Plus manifold it took me 5 months :eek:


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 ;)

rlee429 11-11-2009 10:16 PM

welding looks so fun =) GL on the project.

OhBe1 11-12-2009 04:24 AM

What are your expectations from this effort?

GEE-OTTO 11-12-2009 06:20 AM

Quote:

Originally Posted by OhBe1 (Post 2702265)
What are your expectations from this effort?


Well i was always told dont say something if you don't plan to do it :lol: 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 ;)

katalyst 11-12-2009 07:44 AM

props

in for some sound clips. looks like it was pretty fun putting this together

CasopoliS 11-12-2009 07:51 AM

fun project... you just messed up how the pulses merge but I guess its not that important.

GEE-OTTO 11-12-2009 09:36 AM

Quote:

Originally Posted by CasopoliS (Post 2702394)
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

OhBe1 11-12-2009 10:02 AM

So, for sound only, then (besides the fact that you can, of course)?

GEE-OTTO 11-12-2009 11:05 AM

Quote:

Originally Posted by OhBe1 (Post 2702553)
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 :redface:

burnout8488 11-12-2009 11:53 AM

I like you.

GEE-OTTO 11-12-2009 11:57 AM

Quote:

Originally Posted by burnout8488 (Post 2702739)
I like you.

:wub::lol:

shtbxr22 11-14-2009 07:20 PM

no, no, no. this is not right. :(

shtbxr22 11-14-2009 07:21 PM

you're not done yet......

GEE-OTTO 11-16-2009 07:05 AM

Quote:

Originally Posted by shtbxr22 (Post 2705893)
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 :lol:

GEE-OTTO 11-16-2009 07:06 AM

You are right I have to shorten another primary the number 2 :(


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