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SVT Shelby GT500
Boss 302 Quad Pipes on a GT500
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<blockquote data-quote="Tob" data-source="post: 11106327" data-attributes="member: 83412"><p>I've been picking at this during my spare time. Most of it has been research. I always try to see how far down it is before jump...<img src="data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7" class="smilie smilie--sprite smilie--sprite2" alt=";)" title="Wink ;)" loading="lazy" data-shortname=";)" /></p><p></p><p>I figured it made sense to locate the quad pipe exit first, then work my way back to the 5.4 H/X pipe connection. I found a gentleman on "The Mustang Source" willing to take a couple of shots of the exit/chassis connection on his Boss 302 for me...</p><p></p><p>[ATTACH=full]239353[/ATTACH]</p><p></p><p>[ATTACH=full]239354[/ATTACH]</p><p></p><p>Same connection on each side of the 2012 Boss 302, a nut located just aft of a longer oblong hole with the nut located up and inside the rocker. A quick look at the same location on my '09 chassis...</p><p></p><p>[ATTACH=full]239355[/ATTACH]</p><p></p><p>I have neither hole, fore or aft ('11 and later GT500 owners - do you have these threaded holes?). Then I remembered I had seen a photo that showed a '12 Boss that looked a little different. I searched and found a photo of an early Boss that was displayed on its side at a Woodward Dream cruise. Zooming in and studying the affected area closely, I saw that Ford had welded a nut to the underside of the rocker at this critical junction</p><p></p><p>[ATTACH=full]239356[/ATTACH]</p><p></p><p>Mulling it over for awhile, I figured I could mimic that or...drill a hole and invert a nut with integral washer assembly by slipping it up through the oblong hole and dropping the nut portion down. A tack and I'd be done.</p><p></p><p>Either way, I visited my local Ford dealer parts desk. The guys there are great and always take their time to help me out. I made sure I brought some backup with me to try to simplify things</p><p></p><p>[ATTACH=full]239357[/ATTACH]</p><p></p><p>I was surprised at how I was able to provide clearer data/illustrations than what they had at their disposal. Ambiguous wording, no specific Boss 302 exhaust listings (once again, you search through 5.0 GT entries to find Boss parts), and photos that are less than clear. My parts guy told me that Ford uses different verbage between service manuals and what they have at their fingertips. I stood there and he showed me the monitor all the while so that I could see how screwed up the system is when searching for somewhat "unique" parts. In any case, we could not find a clear view of a '12 chassis that showed the inverted nut that supports the exit point, nor could we find a shot/part number for the early development welded nut below the rocker.</p><p></p><p>Again, no biggie, I'd just have to do it my way instead of being able to use a factory part.</p><p></p><p>Since I'll be fabricating the short run of pipe from the H-pipe to the flanged connection (where the quad pipes begin), I needed a few things. I had planned on cutting my own flanges from some flat stock until I noticed that Ford included a spacer plate (Ford engineers allegedly included this so that Boss owners can bolt in a cut out system and just toss the spacer plate) that gets sandwiched between two other flanges, as well as steel gaskets, etc. </p><p></p><p>[ATTACH=full]239358[/ATTACH]</p><p></p><p>The plate is thick enough that I can weld some 2" pipe inside it just like the factory piece uses.</p><p></p><p>[ATTACH=full]239359[/ATTACH]</p><p></p><p>[ATTACH=full]239360[/ATTACH]</p><p></p><p>I also happened to be using some stainless shim stock (1/8") at work that I can use to make my own exhaust discs, each set with progressively larger hole diameters.</p><p></p><p>[ATTACH=full]239361[/ATTACH]</p><p></p><p>As to the short run of 2" tubing that I need for each side, I visited a few parts counters followed by some local exhaust shops. I struck out at each. Nobody uses stainless tubing when they replace newer systems (aside from using factory parts from Ford), just aluminized steel at best. Scouring the web, I found and ordered some T304 stainless tubing from <a href="http://vibrantperformance.com/catalog/index.php?cPath=1022_1065" target="_blank">Vibrant Performance</a>. I ordered a length that includes bends in it so that I can weld everything up and be done with it.</p><p></p><p>I was going to drill/weld in a nut on each side and quickly realized that the GT500 rock deflector has to be removed (Ford never installed them on Boss exhaust systems either). Three fasteners on each side and they are off quickly.</p><p></p><p>[ATTACH=full]239362[/ATTACH]</p><p></p><p>Laying on my back and holding a quad pipe in the general area it will soon reside in, I noticed that the connection I need to add at my factory H/X pipe is not exactly lined up with the crossover portion but instead closer to the front of the car. I figured I could cut open or tweak the system and shorten it to my liking. I unbolted the clamp that releases the flex pipe/flanged section, figuring I could nip one or the other a minor amount...</p><p></p><p>[ATTACH=full]239363[/ATTACH]</p><p></p><p>Note the restrictive, emasculated section in the middle of the following shot...</p><p></p><p>[ATTACH=full]239364[/ATTACH]</p><p></p><p>The quad pipe tubes neck down to an approximately 1-3/4" pipe (just prior to the flattened 1" tall section, cripes!) diameter. Funky, and different than the quad pipes I had seen in early Ford media shots. Notice the longer flex section in the following shot as well as the fact that it doesn't go through as many diameter changes. The 1/2" flange spacer is missing as well...</p><p></p><p><img src="http://image.mustangmonthly.com/f/34838361/mump_1011_07_o+2012_ford_mustang_boss_302+quad_exhaust_system.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Why would Ford make so many detail changes in what should be a simple section of exhaust pipe? Were they addressing supplier issues or maybe they were still fine tuning the tone from the system. Hmm, well looky at what I found inside the 1-3/4" section...</p><p></p><p>[ATTACH=full]239365[/ATTACH]</p><p></p><p>I thought "You're kidding me. Looks like a muffler baffle from a Briggs and Stratton engine on a Sears lawn mower had been jammed into the pipe. And at 4" long, why? Was the pipe too damn loud without it? I thought that was what the removable restrictor plate was for. WTF..."</p><p></p><p>Coloncam time! El clicko...</p><p></p><p>[ATTACH=full]239366[/ATTACH]</p><p></p><p>That baffle knocks the ID of the quad pipe down to 13/16"! Faced with with making a choice at this point, I punted, as I want time to think this thing over. I can simply cut out the baffle and weld in a section of stainless tube. That might upset the balance, having much of the pre-muffler exhaust bellowing out the side while the remaining exhaust exits fairly quietly out the back. It also might backfire like a bitch, I dunno. I could restrict the sound with varying plates or the electric cutout from Quick Time Performance. Or it may sound like ass no matter what I do. I may leave it in...</p><p></p><p>I just can't believe how small that tubing is restricted to. More when my stainless tubing arrives.</p></blockquote><p></p>
[QUOTE="Tob, post: 11106327, member: 83412"] I've been picking at this during my spare time. Most of it has been research. I always try to see how far down it is before jump...;) I figured it made sense to locate the quad pipe exit first, then work my way back to the 5.4 H/X pipe connection. I found a gentleman on "The Mustang Source" willing to take a couple of shots of the exit/chassis connection on his Boss 302 for me... [ATTACH=full]239353[/ATTACH] [ATTACH=full]239354[/ATTACH] Same connection on each side of the 2012 Boss 302, a nut located just aft of a longer oblong hole with the nut located up and inside the rocker. A quick look at the same location on my '09 chassis... [ATTACH=full]239355[/ATTACH] I have neither hole, fore or aft ('11 and later GT500 owners - do you have these threaded holes?). Then I remembered I had seen a photo that showed a '12 Boss that looked a little different. I searched and found a photo of an early Boss that was displayed on its side at a Woodward Dream cruise. Zooming in and studying the affected area closely, I saw that Ford had welded a nut to the underside of the rocker at this critical junction [ATTACH=full]239356[/ATTACH] Mulling it over for awhile, I figured I could mimic that or...drill a hole and invert a nut with integral washer assembly by slipping it up through the oblong hole and dropping the nut portion down. A tack and I'd be done. Either way, I visited my local Ford dealer parts desk. The guys there are great and always take their time to help me out. I made sure I brought some backup with me to try to simplify things [ATTACH=full]239357[/ATTACH] I was surprised at how I was able to provide clearer data/illustrations than what they had at their disposal. Ambiguous wording, no specific Boss 302 exhaust listings (once again, you search through 5.0 GT entries to find Boss parts), and photos that are less than clear. My parts guy told me that Ford uses different verbage between service manuals and what they have at their fingertips. I stood there and he showed me the monitor all the while so that I could see how screwed up the system is when searching for somewhat "unique" parts. In any case, we could not find a clear view of a '12 chassis that showed the inverted nut that supports the exit point, nor could we find a shot/part number for the early development welded nut below the rocker. Again, no biggie, I'd just have to do it my way instead of being able to use a factory part. Since I'll be fabricating the short run of pipe from the H-pipe to the flanged connection (where the quad pipes begin), I needed a few things. I had planned on cutting my own flanges from some flat stock until I noticed that Ford included a spacer plate (Ford engineers allegedly included this so that Boss owners can bolt in a cut out system and just toss the spacer plate) that gets sandwiched between two other flanges, as well as steel gaskets, etc. [ATTACH=full]239358[/ATTACH] The plate is thick enough that I can weld some 2" pipe inside it just like the factory piece uses. [ATTACH=full]239359[/ATTACH] [ATTACH=full]239360[/ATTACH] I also happened to be using some stainless shim stock (1/8") at work that I can use to make my own exhaust discs, each set with progressively larger hole diameters. [ATTACH=full]239361[/ATTACH] As to the short run of 2" tubing that I need for each side, I visited a few parts counters followed by some local exhaust shops. I struck out at each. Nobody uses stainless tubing when they replace newer systems (aside from using factory parts from Ford), just aluminized steel at best. Scouring the web, I found and ordered some T304 stainless tubing from [URL="http://vibrantperformance.com/catalog/index.php?cPath=1022_1065"]Vibrant Performance[/URL]. I ordered a length that includes bends in it so that I can weld everything up and be done with it. I was going to drill/weld in a nut on each side and quickly realized that the GT500 rock deflector has to be removed (Ford never installed them on Boss exhaust systems either). Three fasteners on each side and they are off quickly. [ATTACH=full]239362[/ATTACH] Laying on my back and holding a quad pipe in the general area it will soon reside in, I noticed that the connection I need to add at my factory H/X pipe is not exactly lined up with the crossover portion but instead closer to the front of the car. I figured I could cut open or tweak the system and shorten it to my liking. I unbolted the clamp that releases the flex pipe/flanged section, figuring I could nip one or the other a minor amount... [ATTACH=full]239363[/ATTACH] Note the restrictive, emasculated section in the middle of the following shot... [ATTACH=full]239364[/ATTACH] The quad pipe tubes neck down to an approximately 1-3/4" pipe (just prior to the flattened 1" tall section, cripes!) diameter. Funky, and different than the quad pipes I had seen in early Ford media shots. Notice the longer flex section in the following shot as well as the fact that it doesn't go through as many diameter changes. The 1/2" flange spacer is missing as well... [img]http://image.mustangmonthly.com/f/34838361/mump_1011_07_o+2012_ford_mustang_boss_302+quad_exhaust_system.jpg[/img] Why would Ford make so many detail changes in what should be a simple section of exhaust pipe? Were they addressing supplier issues or maybe they were still fine tuning the tone from the system. Hmm, well looky at what I found inside the 1-3/4" section... [ATTACH=full]239365[/ATTACH] I thought "You're kidding me. Looks like a muffler baffle from a Briggs and Stratton engine on a Sears lawn mower had been jammed into the pipe. And at 4" long, why? Was the pipe too damn loud without it? I thought that was what the removable restrictor plate was for. WTF..." Coloncam time! El clicko... [ATTACH=full]239366[/ATTACH] That baffle knocks the ID of the quad pipe down to 13/16"! Faced with with making a choice at this point, I punted, as I want time to think this thing over. I can simply cut out the baffle and weld in a section of stainless tube. That might upset the balance, having much of the pre-muffler exhaust bellowing out the side while the remaining exhaust exits fairly quietly out the back. It also might backfire like a bitch, I dunno. I could restrict the sound with varying plates or the electric cutout from Quick Time Performance. Or it may sound like ass no matter what I do. I may leave it in... I just can't believe how small that tubing is restricted to. More when my stainless tubing arrives. [/QUOTE]
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