STAGE 2 Install How-To w/pics

[def]

Not much of a template though, since they are both pictures of one. Does anyone know if there is there a printout (to make it more precise)?

I'm waiting to hear back about picking up a local used stage 2. If it's a jenspeed, I'm going to purchase it, and would love to have a body shop do the cutout for me (dealer = $$$$$$)

Thanks,

[waydui]

Originally Posted by def

Does anyone know if there is there a printout (to make it more precise)?

Hi Kevin,
I still have the original sheet template that I used to cut mine out. It's actual size and has the measurements printed on it.

I can fax or e-mail a PDF of it to you. Let me know.

Regards,
Wayne

[def]

PM sent, thanks wayne!

[Serebo1]

Originally Posted by waydui

Hi Kevin,
I still have the original sheet template that I used to cut mine out. It's actual size and has the measurements printed on it.

I can fax or e-mail a PDF of it to you. Let me know.

Regards,
Wayne

Might be a good thing to have in the library. As long as it's scanned flat, most people can blow it up to scale following the dimensions....

[Toad]

Great info. Very straightforward. Is this in the uberthread? It should be.

I installed mine last night. Did not need Rhino Ramps or any type of lift. Also did not need to remove the undertray; just the rear diffuser.

The PB Blaster was very helpful as it was still a bitch to get the old exhaust out of there. I just ended up wiggling it up and down and it eventually came out. You aren't kidding that stock muffler is HUGE!

Only problem I encountered believe or not was reinstalling one of the hanger mounts on the passenger side, as the holes weren't matching up. Of course I was reinstalling it at night in my apt. complex garage w very poor lighting. I also notice some burning smell, which I assume is burnoff of the PB blaster.

Otherwise it now sounds like a beast much better that the "fartcan" stock exhaust. Thanks Matt for the exhaust.

[Transonic]

Great write up, I'll be sure to save the thread.

Two quick questions though regarding the exhaust clamp. You mentioned it was spot welded to the exhaust. You used PB Blaster (is this the stuff?) to remove it. Would that be the same as using liquid wrench or even WD-40 or is the PB Blaster definitely needed? And #2, one T-Clamp and you're all set? No need for anything to "glue" it in place?

[Toad]

I don't think there should be anything to glue, just clamp. In fact I didn't see any loctite on any of the bolts.

[waydui]

Originally Posted by Transonic

Two quick questions though regarding the exhaust clamp. You mentioned it was spot welded to the exhaust. You used PB Blaster (is this the stuff?) to remove it. Would that be the same as using liquid wrench or even WD-40 or is the PB Blaster definitely needed? And #2, one T-Clamp and you're all set? No need for anything to "glue" it in place?

Hi Transonic,
I'm sorry but I wasn't very clear about the clamp process.

I wanted to use the SAME clamp that came with the OEM exhaust on the Stage II. I had to CUT IT OFF with a Dremmel cutoff wheel because the original clamp was spot welded to the stock exhaust.

However, the original clamp was too big for the Stage II exhaust pipe, so I ended up buying a 2.5" T-Clamp instead.

Yes, you have the right PB Blaster product. I think PB Blaster works better than WD-40, but that's just my opinion.

No, there is nothing to glue. The T-clamp holds everything together just fine.

Regards,
Wayne

[waydui]

Due to several requests, I am attaching a PDF file of the Diffuser Template cutout.

NOTE: BE SURE TO UPSIZE THE TEMPLATE TO 115% TO COMPENSATE FOR SHRINKAGE IN DIGITIZING IMAGE.

Use this to cut out an enlarged opening for the Stage II exhaust. The aluminum cuts easily, but make sure you smooth out the edges, removing any burrs, etc.

Regards,
Wayne

[mattwhite]

Originally Posted by brgm100

I installed mine last night.

Glad to see you got it on. Did you cut the diffuser yourself?

[Toad]

Glad to see you got it on. Did you cut the diffuser yourself?

Hi Matt,

I'll probably cut it tommorrow, since the picnic thing got cancelled and the weather is crappy. Wayne sent me the .pdf. I picked up the Dremmel at Sears today.

[Toad]

Computer question.

Is there a way to get this .pdf to "scale" correctly to a printer or plotter? I tried many different paper settings to try to match the radius numbers and other measurments and did not have any luck.

[def]

Uh oh, I just printed it out and didn't even think about the right proportions...
I'm taking my car today after work to have 15k service, new tires, and diffuser cut by the shop. Let me know what you find... asap

[def]

OK so I just printed out another copy, and took it to the copy machine... I did some quick (wrong) math, so I had to print out a few copies, but looks like blowing it up 115% did the trick (11x17 paper). The "56.9" figure looks off a little, but the rest are all perfect....

I don't have my car here at work due to rain (gotta go home and switch cars to take it to service). Otherwise I'd be able to hold up the cutout to the current diffuser hole. Are you sure we need to blow this up... Wayne did you? Anyone?

[shay2nak]

I had a hell of a time trying to remove the stock exhaust as well, but didn't realize the stock clamp is welded onto the exhaust! I had to put everything back together again and take the car out for a spin to make sure all was well. When you speak of burnoff, I had a scare during my drive...I sprayed WD40 on the stock clamp and the driver's side hanger. I tried to wipe as much of it off as I could before I reassembled everything and when I went driving soon after, I could see smoke coming from my rear tire!!! I was at a stop light and just looked in my side mirror and saw it. Anyway, pulled over right away and had my extinguisher in sight as I checked it out. Turns out the smoke was coming from around where the clamp is. Anyway, it smelled like WD40 also. I kept driving for another 5 miles came home and it's still burning off the WD40!!!

WD40 isn't flammable is it?? My car didn't catch fire so I guess it's a NO. Only when it's being sprayed out of the can? I'm going to try to install the exhaust next weekend and hopefully I won't need to spray it again.

[waydui]

Originally Posted by def

Are you sure we need to blow this up... Wayne did you? Anyone?

I DID NOT blow up the document, I used as it is and did not have any issues cutting out the enlarged area to the right size.

The PDF itself is only a few millimeters (2-3mm per locus) off the diagram specs. There was more than enough clearance once I cut the diffuser.

Regards,
Wayne

[waydui]

Originally Posted by shay2nak

WD40 isn't flammable is it?? My car didn't catch fire so I guess it's a NO. Only when it's being sprayed out of the can? I'm going to try to install the exhaust next weekend and hopefully I won't need to spray it again.

Actually WD-40 IS flammable, but it has a high flash point and needs a spark or flame to ignite it. WD-40 is essentially kerosene.

WD-40 on a hot manifold or exhaust will just smoke until it all burns off.

DO NOT put an open flame to WD-40 or you will have a fire.

FWIW, I use PB Blaster and like it better than WD-40.

Regards,
Wayne

[Toad]

OK so I just printed out another copy, and took it to the copy machine... I did some quick (wrong) math, so I had to print out a few copies, but looks like blowing it up 115% did the trick (11x17 paper). The "56.9" figure looks off a little, but the rest are all perfect....

I don't have my car here at work due to rain (gotta go home and switch cars to take it to service). Otherwise I'd be able to hold up the cutout to the current diffuser hole. Are you sure we need to blow this up... Wayne did you? Anyone?

Thanks for the tip. I just did the same thing, blowing it to 115 and the measurements look good. I had to use 2 legal size sheets of paper, which I'll have to tape together.

When I did they 8.5 x 11, the "extended" area matched up to the original size of the hole.

[def]

OK I just called Thom at FVMC (where I bought the exhaust). He pulled out a template and we DO need to blow up the PDF template above by 115%. The measurements should be correct in MM. Wayne, I'm not sure if it shrunk after it was faxed or which sized you used (obviously it worked out great for you, so it doesn't matter), but I will use the enlarged one.

Might want to make a note of that in your post with the .pdf file, but I'll provide some picts of mine (hopefully) soon.

Thanks for the help guys,

[waydui]

Originally Posted by def

Might want to make a note of that in your post with the .pdf file

Hi Kevin,
Thanks for following up on this. I edited my post to reflect resizing issue.

Hope it works for you.

I'm sure you'll love the sound!!!

Regards,
Wayne