Mustang X-pipe

Let Your Ponies Be Heard – Exhaust Component R&D, Part 3: The X-Pipe

Last time we took a look at what went into creating the jig for our Mustang H-pipe. This same process will be applied to create a jig for our Mustang X-pipe designs. We have plans laid out to create three different X-pipe designs to test on the Mustang GT.

It is interesting that the same jig will be used for each of the three X-pipe designs. This is possible because the section that is changing between each X-pipe is the actual X in the center of the pipe. The jig’s job is to ensure that the piping coming both into and out of the X itself will fit with the rest of the Mustang GT exhaust system. The center design is unrestricted by the jig, and therefore we have some room to play with the design.

We plan to create different degree bends for the X part of the pipe: a 60° X-pipe, a 45° X-pipe, and a 20° X-pipe. We will test these three designs to see if there is any benefit to using these various X designs on our GT.

But first fabrication! After the piping was laid out in the jig, we could design our X in the center. The first X to be designed is our 45-degree X. This one is the most intricate and fabrication will be the most involved. Each corner of the center X was cut and tacked together, and then carefully welded so as to not warp the metal and change the shape of our X. The result is a very cool-looking X, check out some photos of our first prototype below.

Creating the Mustang X-pipe
Creating the Mustang X-pipe
Creating the Mustang X-pipe
Creating the Mustang X-pipe

Our first X-pipe is finished and sitting nicely in the jig. Several small posts are tack-welded into place on our X-pipe. This is to ensure that the piping does not warp as the metal heats up during the welding process. We added them in as an extra precaution when fabricating our prototype and they will not be present on the finished product. Take a look at the X-pipe resting in our jig.

Mustang X-pipe in the jig
Mustang X-pipe in the jig
Mustang X-pipe in the jig
Mustang X-pipe in the jig
Mustang X-pipe center design
Mustang X-pipe center design

Check out the first X-pipe design sitting nicely in place on our Mustang GT.

Mustang GT Exhaust installed on the GT
Mustang GT Exhaust installed on the GT
Mustang GT Exhaust installed on the GT
Mustang GT Exhaust installed on the GT

Next up was our 60-degree X, slightly less intricate but cool none the less! The individual pipes that make up this X are slightly larger, because the bend of the X isn’t as severe, so the sections can be larger. Let’s check out some photos of this X with the welding complete.

Mustang X-pipe
Mustang X-pipe
Mustang X-pipe
Mustang X-pipe

…and some of the Mustang X-pipe installed on our GT.

Mustang GT Exhaust Installed
Mustang GT Exhaust Installed
Mustang GT Exhaust Installed
Mustang GT Exhaust Installed

Finally, we have our 20-degree X. We thought this X section might be the simplest to construct; however, it was to be somewhat challenging to weld the sections of pipe with this design. Still, we were able to execute the design and it turned out just as nice looking as our other two renditions.

Mustang X-pipe
Mustang X-pipe
Mustang X-pipe
Mustang X-pipe
Mustang X-pipe
Mustang X-pipe

Coming Up!

Next up is the fun part, testing! Although we do not anticipate that this modification alone would make power on the GT, we still need to test out our work. We will test for power gains but more importantly, we want to find out if one design is superior to the others. Check back next time for results!

Thanks for reading!

-Sara

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