Project WidowMaker - The Build Thread

[The WidowMaker]

so i had some decisions to make on the mufflers. the wife wanted it quieter than before, but i still wanted it to sound good. i ended up buying the stainless 50 series deltas back in december when bing was giving 20% off ebay purchases. ever since then i have somewhat regretted not going with the 40 deltas like i had before. i figured that the bigger motor and larger piping would make it louder, but that the increased insulation, carpet and x-pipe would mellow it out a little. a wash? im not sure.

since i had to open one up (i'll get to that later) and i had already polished them and couldnt return them, i had three choices. leave them as is, weld up the resonator chamber in each muffler essentially making it just a longer 40, or removing the extra 4" and making a 40 series. i ended up just leaving them as is, but if i want it louder after its been on the road, i will take the full 4" out at that time.

then there was the other issue (the part i said i would get to). flowmaster only makes one part number per style (inlet/outlet) of muffler. so, if you need two mufflers with offset inlets that are next to each other (our chevelles), one muffler has to be flipped over. when you flip a flowmaster, you get the ugly case seam. and since i was polishing them, that wouldnt work. below are the pics of what i ended up doing. cut the end off and grind away their weld until the stamped plug end was back to normal. then just flip, reinsert and reweld. now i have a matched set.......

here you can see the inlet side of the muffler. the small hole to the right is the inlet to the resonator chamber. that is what i had planned to weld up.



here it is flipped and rewelded. i cant get any good pics of the welds. they just look blurry.

[The WidowMaker]

here are the rest of the exhaust pics. about 100 hours later and i never imagined it taking this long. but i am damn happy to be done.... well somewhat. i need to learn how to tig with filler a little better so i can attach the hangers that are just tacked on.

like i said before, an average of a B/B+ on weld appearance. some are D's mainly on the right rear tailpipe since i did it first, but there are a few A's as well. did i heat it too much and lose the stainless properties? only time will tell. i have a pretty good rainbow effect, and the haz isnt too wide, so i hope im fine.

the first two show how the frame was cut to allow the exhaust to sit up higher. i would have loved to have made them go through the frame for a little more rigidity, but i would have needed another two vband clamps to make it work and the hole for those flanges needs to be pretty big. i also got the mounts from the roadster shop. im hoping i dont end up melting the ones closer to the motor.



the exhaust will exit through the valance below the bumper. i have some transitions to make the tips 3" and i plan to make them slightly oval. that work will come once the frames done and the bumper gets completed.



here you can see the tight spot. if i would have welded the watts connector on at more of an angle and given myself another 1" of clearance, i would have saved a few days work. this was a TOTAL PAIN IN THE ASS!!!!! the watts crossmember had to be notched to make it work. this was another time where changing build plans bit me in the ass. i never expected to have the car so low that 1/4" of travel mattered. the rear never went this low when i set up the watts since it wasnt until after that i notched the fram.

[tones2SS]

WOW!!! You are doing a great job on this car. The welds look really good to me. Keep up the great work and keep us posted. I can't wait to see this bad boy complete!

[The WidowMaker]

i can't wait either. the body will get pulled off next week so i can start finishing up the frame prior to paint. i hope to have it all nice and pretty in one month.

[tones2SS]

Very cool man!

[The WidowMaker]

today was the first of 10 work days to get the frame off to the blaster. i actually made a timeline, and if i stick to it, i will have frame paint pics on the 31st of this month.

today the body got pulled and put on stands in the garage. i then had to pull the motor and trans and get the frame up on the rotisserie. i also started to weld up the rear section of the frame that was notched for the exhaust.

so, 1 day down and 9 to go. and im currently on schedule!!!! days 2-5 will come at the end of next week on my 4 day. i work a few shifts with a damn wedding in between.

[tones2SS]

Very cool. I will be on the lookout for the updates. Have fun man!

[The WidowMaker]

here are a few pics from today. i got both sides fully notched and cleaned up in the rear. i had planned on welding up the 4" holes in the mid cross, but that will be tomorrow morning.

you can also see how much having the body on the jack stands and the frame on the rotisserie screws up the garage. if its the other way around, the body can hover on the rotisserie almost above the frame and take up a ton less room. i cant wait until the frame is on the ground for good!!!!

[ANVIL1]

I have to say, I'm really impressed especially since it's your first build. Nice work!

[tones2SS]

Looks awesome! Good job!