How to Make an Exhaust Cutout

Written by corey morris
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How to Make an Exhaust Cutout
Use an exhaust cutout to get the most from your car's exhaust system. (Jupiterimages/ Images)

Creating an exhaust cutout is a way to get the most from your vehicle's exhaust system. Cutouts allow your vehicle to run most of the time but can become noisy when the car runs at full throttle. Making your own cutout with a few materials found around the garage can help save the money it would cost to purchase a cutout from a dealer.

Skill level:
Moderately Challenging

Things you need

  • Grinder
  • Stainless-steel plate
  • Slip-fit exhaust adaptors
  • Jigsaw
  • Welder
  • Welding mask
  • Rotary tool
  • Steel hinge
  • Coloured spray paint
  • Exhaust clamps

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  1. 1

    Use a grinder to cut five rectangles from a stainless-steel plate measuring 1/16 inch thick. Two rectangles should measure 12 by 3 inches, and three should measure 12 by 6 inches. These pieces will become the sides and top and bottom of the cutout, respectively. Cut an additional two rectangles measuring 3 1/4 by 6 1/4 inches, which will serve as end plates for the exhaust.

  2. 2

    Weld slip-fit exhaust adaptors over the centre of the end plates using a welder and wearing a welding mask. Cut the disk on the end plate with a jigsaw so it can fit inside the adaptor tubes. Use a rotary tool to smooth the connection together between the end plates and adaptor tubes.

  3. 3

    Connect the box and adaptor side of the end plates together using a welder. Check to ensure the end plates face outward. Use your grinder to smooth out any pointed weld marks. Flip the box over, and use the grinder to cut out a rectangle 1/2 inch from the sides and 1 inch from the back of the box.

  4. 4

    Weld one side of a steel hinge to the inside back of the box so the hinge faces upward. Attach the other side of the hinge to the rectangular cutout with the welder so the hinge opens inward. Use the rotary tool to make any connections smooth.

  5. 5

    Use the grinder to cut another plate from the 12-by-6-inch plate. Check to ensure this cut measures 1 inch from the sides and 1 1/4 inch from the front and back. This plate will act as the flange for the rectangular cutout. Weld the flange to the bottom of the exhaust assembly.

  6. 6

    Spray your vehicle's exhaust pipes with a coloured spray paint. Drive your car for a mile or so at full throttle to release optimal exhaust. Park the car, and inspect the pipes. Plan to station the cutout in the areas where the paint has burnt off. Cut the exhaust pipe with the grinder at the edges of the areas where the paint has burnt off.

  7. 7

    Slide exhaust clamps over the front and rear extensions on the cutout, then place the cutout over the cut pipe. Tighten the clamp with a ratchet and socket set to ensure the cutout remains in place.

Tips and warnings

  • Always use a welder's mask when welding.

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