Chevy Corvette Z06 - Unleash The Fury

This is the pipe that's in use when the exhaust-control butterfly opens. The baffling keeps noise levels down to factory specifications, but Kile will be covering this drilled pipe with a solid one.

After measuring, Kile cuts the exhaust tubing to the specified length. He then makes a cut down the length of the tubing, so it can be wrapped around the existing baffled pipe.

Kile uses a large pair of pliers to squeeze the tubing and fit it around the drilled pipe. There will be a small gap in the tubing, but he'll fabricate a filler piece to make it solid.

Here's the finished product before the insulation goes back in. There's no need for grinding, so Kile allows the metal to cool for a few minutes and repacks the insulation.

Now Kile can reinstall the panel he cut out to access the pipe. He first tack-welds it, so he can make any adjustments to align the panel, and then stitch-welds the panel until it's completely solid.

Kile welds a succession of 2-inch beads along the filler piece on both sides and proceeds to weld the ends of the pipe as well. Make sure to use regular steel tubing, as it welds much better than aluminized exhaust pipe.

As with the welding process, it's important to keep heat from distorting the metal while grinding it smooth. Kile wants the mufflers to have a factory look, so he goes the extra mile with the grinder.

A coating of high-temp silver paint is the last step to the muffler mod, as it keeps the bare metal from rusting. Kile repeats the steps on the other muffler and reinstalls the pair before calling it a day.

When the car is on the ground, you'll never know it has custom mufflers on it. But anytime the exhaust goes into "wild" mode, there'll be no denying it.