Electric / Turbine Powered Rover MGF - (9)

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Motivation on the exhaust fabrication was at a minimum for me, so luckily me ole mate Anton was able to give me a much needed kick up the backside whilst giving me a bit of a hand. The exhaust route is not straight forward to say the least, but it seemed logical to start with some pre-bent 6" stainless steel pipes.

A small hole that fortunately didn't interfere with the structural integrity of the car has been cut out to allow the passing of the exhaust tube. I new where the final part of the exhaust was going to be, the trick was routing this to the engine. We cut the stainless pipes in to sections and using a couple of spot welds per join we were able to form a respectable pipe assembly with what I would imagine would allow a fairly smooth gas flow.

The pipe doesn't actually make contact with the engines exhaust, there is a 3mm gap all the way round, this is required as the engine is shock mounted and the exhaust is not. The next step will be to try to find a 6" trumpet inlet and this will allow for a small quantity of induced cool air in to the exhaust.

In theory, as long as the final box (silencer) is secured firmly there will be no need to mount or secure the exhaust in the engine compartment.
Profile is looking good so far.

Exhaust removed for final welding and Anton pretending it's a Tuba I guess.

The boot air vent being opened up to allow a space where the exhaust can protrude.

A small stainless rectangular surround plate might just make the hole look a little less boring.
The exhaust exit slot has now been cut out to an area of 30sq", thus the rectangular hole is about 2sq" bigger than the pipe diameter, hopefully this will help to reduce the inevitable back pressure caused by transferring from a round exhaust to a square exit.

To direct the flow of gas I have made an internal guide plate, firstly from cardboard, then aluminium and then finally out of 1mm stainless steel, this was made last because of the awkwardness of profiling such a hard metal.
The bends were made by wrapping around various sizes of round tube, this is the final version ready to be welded in to the exhaust pipe.

This picture shows the guide welded in to place and the end which was surplus to requirements has now been cut off and discarded.
I have now started to make the guide plates that will direct the gas flow out of the exhaust to atmosphere, the plasma cutter and grinder were mainly used to get the results required.

This will be the end plate of the exhaust, the lip on the left is where the plate will attach to the bracket fixed on the car.
The gas flow of the exhaust has caused me concern for quite a while now and for an initial test I have made use of a smoke machine to gauge the characteristics of the exhaust flow.
The next step was to add some proper pressure behind the gas flow by making use of my DIY Turbine. A video of the run can be seen on the media page here, the P2 pressure was at 1 Bar and pushing on the exhaust could not be felt when placed in the efflux, in fact it seemed to silence slightly as well, so far so good.

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