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Performance Exhaust Systems: How to Design, Fabricate, and Install
The photos in this edition are black and white.
To extract maximum performance, an engine needs an efficient, well-designed, and properly tuned exhaust system. In fact, the exhaust system's design, components, and materials have a large impact on the overall performance of the engine. Engine builders and car owners need to carefully consider the exhaust layout, select the parts, and fabricate the exhaust system that delivers the best performance for car and particular application.
Master engine builder and award-winning writer Mike Mavrigian explains exhaust system principles, function, and components in clear and concise language. He then details how to design, fabricate, and fit exhaust systems to classic street cars as well as for special and racing applications. Air/exhaust-gas flow dynamics and exhaust system design are explained. Cam duration and overlap are also analyzed to determine how an engine breathes in air/fuel, as the exhaust must efficiently manage this burned mixture. Pipe bending is a science as well as art and you're shown how to effectively crush and mandrel bend exhaust pipe to fit your header/manifold and chassis combination. Header tube diameter and length is taken into account, as well as the most efficient catalytic converters and resonators for achieving your performance goals. In addition, Mavrigian covers the special exhaust system requirements for supercharged and turbocharged systems.
When building a high-performance engine, you need a high-performance exhaust system that's tuned and fitted to that engine so you can realize maximum performance. This comprehensive book is your guide to achieving ultimate exhaust system performance. It shows you how to fabricate a system for custom applications and to fit the correct prefabricated system to your car. No other book on the market is solely dedicated to fabricating and fitting an exhaust system in high-performance applications.
Acknowledgments
Introduction
Chapter 1:
Theory, Design and Principles
Intake Air
Carburetors
EFI Throttle Bodies
Mass Airflow Sensors
Fuel Injector Sizing
Intake Manifolds
Cylinder Heads
Camshafts
Special Firing-Order Camshafts
Exhaust Manifolds
Pumping Loss Reduction
The Four-Stroke Engine Cycle
Oxygen Sensor Technology
Chapter 2:
Exhaust System Component Design, Flow and Function
Exhaust Manifolds
Exhaust Headers
Exhaust Manifold and Header Coatings
Exhaust Pipes
Mufflers
Catalytic Converters
Chapter 3:
Exhaust Pipe
Materials
Exhaust Pipe Sizing
Pipe Bending
Pipe Shape
Pipe Material and Coatings
Crossover Pipes
Converting to Dual Exhaust
Exhaust System Supports
Pipe Connections
Sample Exhaust System Installations
2014 Chevy/GMC 1500 Cat-Back Installation
2011 Ford Mustang GT XO-Pipe Installation
Chapter 4: Header Design and Function
Selection Considerations
Header Styles
Materials
Header Coatings
Primary Tubes
Flange Welding
Tube Bending
Header Fabrication
Port Matching and Scavenging
Gaskets and Fasteners
Design Your Own Headers
Chapter 5:
Mufflers and Catalytic Converters
Mufflers
Resonators
Catalytic Converters
Cat-Back Systems
Diagnosing Catalytic Converters
Testing the Converter
Chapter 6:
Supercharged and Turbocharged Systems
Supercharging
Fuel System
Turbocharging
Engine High-Boost Upgrade
Turbocharger Temperature Management
Headers versus Cast-Iron Manifolds
Exhaust Pipe Diameters
Turbocharger Location
Intercoolers
Chapter 7:
Exhaust System Math
Finding Swept Volume
Calculating Primary Tube Size
Pipe CFM
Exhaust Waves
Primary Tube Length
Collector Diameter and Length
Source Guide
The photos in this edition are black and white.
To extract maximum performance, an engine needs an efficient, well-designed, and properly tuned exhaust system. In fact, the exhaust system's design, components, and materials have a large impact on the overall performance of the engine. Engine builders and car owners need to carefully consider the exhaust layout, select the parts, and fabricate the exhaust system that delivers the best performance for car and particular application.
Master engine builder and award-winning writer Mike Mavrigian explains exhaust system principles, function, and components in clear and concise language. He then details how to design, fabricate, and fit exhaust systems to classic street cars as well as for special and racing applications. Air/exhaust-gas flow dynamics and exhaust system design are explained. Cam duration and overlap are also analyzed to determine how an engine breathes in air/fuel, as the exhaust must efficiently manage this burned mixture. Pipe bending is a science as well as art and you're shown how to effectively crush and mandrel bend exhaust pipe to fit your header/manifold and chassis combination. Header tube diameter and length is taken into account, as well as the most efficient catalytic converters and resonators for achieving your performance goals. In addition, Mavrigian covers the special exhaust system requirements for supercharged and turbocharged systems.
When building a high-performance engine, you need a high-performance exhaust system that's tuned and fitted to that engine so you can realize maximum performance. This comprehensive book is your guide to achieving ultimate exhaust system performance. It shows you how to fabricate a system for custom applications and to fit the correct prefabricated system to your car. No other book on the market is solely dedicated to fabricating and fitting an exhaust system in high-performance applications.
Acknowledgments
Introduction
Chapter 1:
Theory, Design and Principles
Intake Air
Carburetors
EFI Throttle Bodies
Mass Airflow Sensors
Fuel Injector Sizing
Intake Manifolds
Cylinder Heads
Camshafts
Special Firing-Order Camshafts
Exhaust Manifolds
Pumping Loss Reduction
The Four-Stroke Engine Cycle
Oxygen Sensor Technology
Chapter 2:
Exhaust System Component Design, Flow and Function
Exhaust Manifolds
Exhaust Headers
Exhaust Manifold and Header Coatings
Exhaust Pipes
Mufflers
Catalytic Converters
Chapter 3:
Exhaust Pipe
Materials
Exhaust Pipe Sizing
Pipe Bending
Pipe Shape
Pipe Material and Coatings
Crossover Pipes
Converting to Dual Exhaust
Exhaust System Supports
Pipe Connections
Sample Exhaust System Installations
2014 Chevy/GMC 1500 Cat-Back Installation
2011 Ford Mustang GT XO-Pipe Installation
Chapter 4: Header Design and Function
Selection Considerations
Header Styles
Materials
Header Coatings
Primary Tubes
Flange Welding
Tube Bending
Header Fabrication
Port Matching and Scavenging
Gaskets and Fasteners
Design Your Own Headers
Chapter 5:
Mufflers and Catalytic Converters
Mufflers
Resonators
Catalytic Converters
Cat-Back Systems
Diagnosing Catalytic Converters
Testing the Converter
Chapter 6:
Supercharged and Turbocharged Systems
Supercharging
Fuel System
Turbocharging
Engine High-Boost Upgrade
Turbocharger Temperature Management
Headers versus Cast-Iron Manifolds
Exhaust Pipe Diameters
Turbocharger Location
Intercoolers
Chapter 7:
Exhaust System Math
Finding Swept Volume
Calculating Primary Tube Size
Pipe CFM
Exhaust Waves
Primary Tube Length
Collector Diameter and Length
Source Guide
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