Project SR E30: Part 8 – Fabricating a Custom Stainless Steel Oval Exhaust
Tig welding an exhaust under the car
The angle of this downpipe to midpipe joint is extremely sensitive. Being off by a couple degrees can drastically change which way the exhaust is pointing. Because of this, it is neccessary to tack weld this joint under the car to get it perfect.
Mocking up BMW E30 SR20DET exhaust
Getting this angle of this joint right was the most difficult task of this entire exhaust project. Every tweak required re-sanding the joint for the pipes the butt up perfectly. In the end, we got it just right.
Back purging stainless steel oval exhaust pipe
Rinse and repeat. Seal, back purge, weld.
BMW E30 last exhaust turn
For the next section, we’re going to make a right turn to point the exhaust towards the bumper opening.
Fabricating custom BMW E30 stainless steel oval exhaust
After that, it’s a straight shot to the back of the car.


    1. At the time, we couldn’t find any decent oval exhaust flanges that wouldn’t have taken away from the ground clearance.

      That being said, the exhaust is actually pretty easy to remove.

  1. Nice work, I was gonna see if you can check out the treehouse racing lollypops. they are smaller in physical size and gain more clearance. Your build reminds me of one of my friends who went KA-t in an e30 and it ran pretty gnar.

    Tip: might want to 2-piece the exhaust for when you need to change out the guibo, subframe bushings, and other rear maintenance.

    1. Yeah we’re definitely going to switch to a heim-style lolipop bushing down the line. I’ve gotten that burning polyurethane smell a couple of times already.

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