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Discussion Starter #1
I need input from you guys!

I was going to make this pipe 3" ID, but before I get too far ahead of myself I wanted to ask everyone if this would be the best size for my casting.

If you guys want 3" and it bolts to the stock catback system that might be best. I will start working on a 3" exhaust system soon, so this pipe will obviously work with whatever cat-back I design.
Plus, if it bolts to stock cat-back, it should be modular with any aftermarket cat-back that connect to the stock downpipe. You just have inside diameter pipe differences.

Let me know. For now, here are some very preliminary CAD screenshots.
I am choosing casting because of that tight space back there. I can get a nice smooth flow by defining the pipe geometry however I want.
I also don't have to worry about welding and weldment fatigue. It is much easier to calculate and design strength into the part this way, especially at the turbo flange.

When I get this 3D printed for test fitment in the next week or two, I will post pictures as well.





 

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I would like a full 3" id but I would need a high flow cat since in cali
 

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I need input from you guys!

I was going to make this pipe 3" ID, but before I get too far ahead of myself I wanted to ask everyone if this would be the best size for my casting.

If you guys want 3" and it bolts to the stock catback system that might be best. I will start working on a 3" exhaust system soon, so this pipe will obviously work with whatever cat-back I design.
Plus, if it bolts to stock cat-back, it should be modular with any aftermarket cat-back that connect to the stock downpipe. You just have inside diameter pipe differences.

Let me know. For now, here are some very preliminary CAD screenshots.
I am choosing casting because of that tight space back there. I can get a nice smooth flow by defining the pipe geometry however I want.
I also don't have to worry about welding and weldment fatigue. It is much easier to calculate and design strength into the part this way, especially at the turbo flange.

When I get this 3D printed for test fitment in the next week or two, I will post pictures as well.


That looks like a nice piece in the screen shots and a 3" turbo-back system is perfect for us and would be good enough for 500hp. I haven't been under the koup yet to see what size they gave us from the factory, but remember, an exhaust system is only as big as it's smallest ID, meaning you can have a 3" downpipe, and a 3" cat-back exhaust, but if you are running a 2.5" cat, then you basically have a 2.5" system. A 3" downpipe is nice, but I would make it to bolt to both the factory cat(neck down), and for a little cheaper price(just weld on the flange), bolt to a 3" cat or test pipe. I don't have emissions, so I would want a complete 3" turbo-back with no resonators, but for people that do have emissions, they would need to stick a cat in there. I only say make it bolt to both the factory cat, and a 3" cat because 3" cats are expensive and if someone doesn't want to pony up for one, so they can pass, then you can still sell your down-pipe to them(broader market = more $) as a true "bolt-on system". BTW, are you planning to make a complete 3" turbo-back system(with or without cats), or are you just starting with a downpipe?
 

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I'd support you in it
 

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Discussion Starter #5
I would like a full 3" id but I would need a high flow cat since in cali
high flow cat will be an option, just not shown in this rendition

That looks like a nice piece in the screen shots and a 3" turbo-back system is perfect for us and would be good enough for 500hp. I haven't been under the koup yet to see what size they gave us from the factory, but remember, an exhaust system is only as big as it's smallest ID, meaning you can have a 3" downpipe, and a 3" cat-back exhaust, but if you are running a 2.5" cat, then you basically have a 2.5" system. A 3" downpipe is nice, but I would make it to bolt to both the factory cat(neck down), and for a little cheaper price(just weld on the flange), bolt to a 3" cat or test pipe. I don't have emissions, so I would want a complete 3" turbo-back with no resonators, but for people that do have emissions, they would need to stick a cat in there. I only say make it bolt to both the factory cat, and a 3" cat because 3" cats are expensive and if someone doesn't want to pony up for one, so they can pass, then you can still sell your down-pipe to them(broader market = more $) as a true "bolt-on system". BTW, are you planning to make a complete 3" turbo-back system(with or without cats), or are you just starting with a downpipe?
I am just starting with a full downpipe that bolts to the OEM cat-back system. A cat-back system will soon follow that will be 3" as well. The downpipe will have cat/no cat option.
 

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I am just starting with a full downpipe that bolts to the OEM cat-back system. A cat-back system will soon follow that will be 3" as well. The downpipe will have cat/no cat option.


Cool, can't wait. Looks like you put some nice products together. I would only do it if I could do the whole thing at once(turbo to tip) as to get the full benefit of the downpipe. I would love for someone to make some parts for my Sportage. I'm less than a year from the 5 year bumper to bumper(even though it only has 30k on the clock) so then I can start playing around with it :D
 

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What price range you aiming for? Would both versions (Cat/no Cat) the same? Looks nice, better flow and help things in the temp department a bit.
 

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Discussion Starter #9
Cat will add to the cost for sure.

I am not sure what the casting will come to cost at the moment. I hope to keep it in the $300-$400 dollar range. Obviously the cheaper that better for everyone, so I'll do my best.
 

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Awesome! I've been looking for a good exhaust system. Very pleased to know you guys are working on one now. By the looks of things my state/county doesn't require emissions check here.. I'm not 100% sure. I don't want to go fail and then have people mad at me and get a ticket for no cat lol! I'm researching more about it.. Because if I don't need a cat. I won't get a cat
 

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Dear Santa, Err I mean 6th.
Please sign me up for a downpipe and exhaust.
I have been good ALL year and have been eating my vegetables.
"I can hardly stand the wait"
 

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Can't wait to see the 6th element stuff coming out this year.
 

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Remember not all Forte SX are manual, Forte5 owners are Auto's, any other size down pipe should be considered too.
One size fits all, just like the Koup the 5 comes as manual trans or automatic.
 

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Forte 5 are Auto's
Sounds like the dealer lied to you just to sell the one he had on the lot or they only bring autos to PR. Here stateside you can get the 5 with either trans
 

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I checked with the Dist. here in PR, all Turbo Forte 5 will only be available with Auto's just for PR, anyway the F5 is fun to drive with the Padle Shifter, love that.
 

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My F5 is a auto and I love it. I really wanted a manual but couldn't find one fully loaded and my wife has medical issues that make a manual hard to drive for her.

The dp will fit the auto also. They both come out the same area as the manual
 
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