i went to bolt up the dp and it would not line up to my cat. either 1) the bend is off by a few degrees, or 2) they welded the dp piping to the turbo-downpipe flange at the wrong angle. looks like a am going to have to get it either bent a few degrees down, or get that flange rewelded. luckily i have a friend who's stepdad is in metalworking. these little discrepancies are starting to anger me :thumbsdown .

Star precision machine work at its finest:rolleyes I love how I only have to use a pry bar to get my O2 in.

yea that o2 sensor is going to be in there pretty snug with the oil pan.

Relocate the O2 bung. I winded up actually breaking an O2 sensor after about a month of driving around. I did it for $5 (cost of the bung) but a regular welder should only charge $20. It's well worth relocating it before you bust a $30 sensor.

no problems here....maybe it's my luck again...the AZ guys would know what i'm talking about...

well looks like i am going to get the flange rewelded at a different angle. i think that if i bend the pipe i will pinch it.

get a flex section on there while your at it.

yea, i was thinking that...where can i purchase a flex section?

here are a few pics...i havent been taking that many but i got bored to day because of the snow outside. lemme know if you see anything out of place..thanks ;)







sorry for the bad angles, not very much space to move around. peace!

Originally posted by davo345
yea, i was thinking that...where can i purchase a flex section?

www.exhaustdepot.com That is where I got mine, I have not put it on yet, but I own it.

And yes, I HATE the star DP. I want someone to make a custom DP, but I can not find anyone to do it.

Originally posted by brynden29

Originally posted by davo345I want someone to make a custom DP, but I can not find anyone to do it.

Ud make a fortune if u could get some custom 3" Star DPs thats bolt-up... And while your at it, some custom 2" IC piping for a 1G SMIC where the damn pipes dont blow off every 200 yards... Ok, your mission has been assigned...

:thumbsup

isnt 3" downpipe a little big?

Originally posted by brynden29

Originally posted by davo345 yea, i was thinking that...where can i purchase a flex section?

www.exhaustdepot.com That is where I got mine, I have not put it on yet, but I own it.

where are you going to weld it in? there are quite a few bends like this: /\/, a little less extreme obviously, if you recall, and i think they measure out to be less than 6"..heh..and the only length of ss flex pipe is usually no less than 6". :shrug

i have found when putting the DP back on its easier if you leave the turbine-exhaust manifold bolts loose enough to be able to move the turbo some AND have the dp hooked to the cat already...this allows you to use a claw hammer to move the turbo and match up the turbo-DP bolts much easier...before doing this i could never get more than 3 bolts to match up now i can get all 5...and your def gonna wanna get a flex section on there...i didn't have one and ended up having my DP torque in half and break twice!....good luck, your gonna love booooost!:thumbsup :cheers

nm

you won't be rotating it...just leave the bolts loose where the turbo connects to the manifold, this will allow the turbo to move some so you can match the DP bolts up easier...

I found it easier to just use 5 studs and screw the studs into the turbine housing, then just use a nut/washer to seal it... That really helps me to line the stupid thing up...

hehe, you caught me before i edited it. ok i will try that. thank you.

anytime...i know they can be a pain in the rear...hope it helps you out..:thumbsup

i was thinking about it, and if i just welded in a nice flex section, i wouldnt even have to reweld the other turbo/dp flange ....i could just FLEX the downpipe into place instead of reangling the whole dp.. DUH:thumbsup . why i think of this at 2:30 in the morning is beyond me though. hehe

now the question is, where on the STAR DP should i weld in the flex section...the piping isnt exactly laid out in a straight line.

i am sorry if this is a newbie Q, but i am a very inexpeienced "novice" welder and am not exactly sure how to go about this. thanks.

weld it in between the cat and the oilpan..only real place to be able to put it in there..

or you could just scrap the Star downpipe all together and get the Chill Factory 3" one.

That's my plan anyway...

Originally posted by Cereal5
or you could just scrap the Star downpipe all together and get the Chill Factory 3" one. That's my plan anyway...

Dude the chill factory is only for the HRC kit... Which usually a totally different DP, and turbo... They only have 3 bolts, and the star turbo housing has 5, thats why I said someone would make a killing off a 3" star DP...
:thumbsup

Originally posted by Justin99RS
weld it in between the cat and the oilpan..only real place to be able to put it in there..

thanks :thumbsup

yeah btwn cat and oil pan, that way your cutting the flange anyways and can rotate it to what you nead and have the flex section.

sigh. this is the last thing i need to do, then i will be boosting around town }( . ive taken my time and i hope it was worth my time. i will let you all know if i have any issues with the welding.

now i just have to wait in anticipation for the flex section to come in :( .

thanks for the help people. i appreciate it.

Good Boosting:thumbsup
Go give em hell}(

wouldn't be difficult to get len to start up 3" dp's for the star kit...

Just about any muffler shop that does "aftermarket" type work should fine it fairly simple to make you a flex-section and install it. least the one dwon the road from my house did. my absolute only problem i encountered with my STAR kit was tightening the damn manifold studs down. had to saw a wrench in half to get to the bottom ones! haha.

1999 Black C5
1997 Silver RS
Wiseco 8.8:1 Pistons(back to low compression!)
Eagle Rods
T3/T4 Turbo
Custom FMIC
Greddy Exhaust
390's
Most current 1/8th mile time: 8.3@90mph 2.015 60'(Nitto Drag radials, i suck)

Originally posted by Nitrous_RS1997
Just about any muffler shop that does "aftermarket" type work should fine it fairly simple to make you a flex-section and install it. least the one dwon the road from my house did.

luckily i have access to a welder. if me and a bud do it ourselves it will defray some of the costs for these other "tweaks" ive had to make to the kit.

Originally posted by Cereal5
wouldn't be difficult to get len to start up 3" dp's for the star kit...

yea i think we should see if len would make us some DP's...i know i'd love to have a 3"