Installing a custom exhaust system with side exit pipes is an excellent way to boost your vehicle's performance, improve exhaust flow, and create a distinctive aesthetic appeal. Side exit exhausts not only provide a unique and aggressive look but can also reduce backpressure, potentially increasing horsepower and torque. This comprehensive guide will walk you through the entire installation process, from preparation to final checks, ensuring a professional and safe upgrade to your vehicle.

Understanding Side Exit Exhaust Systems

Before diving into installation, it’s important to understand what sets side exit exhausts apart from conventional systems. Unlike rear exit exhausts that discharge gases at the back of the vehicle, side exit pipes expel exhaust gases just ahead of the rear wheels, typically along the lower sides of the vehicle. This configuration offers several benefits:

  • Reduced Exhaust Length: Shorter piping can minimize exhaust gas temperature loss and improve flow.
  • Distinctive Sound: Side exit pipes often produce a louder, more aggressive exhaust note due to their proximity to the cabin and reduced muffling.
  • Improved Ground Clearance: Since the exhaust exits before the rear bumper, it can provide better clearance and reduce the risk of damage from road debris.
  • Styling Appeal: Side exit pipes add a custom, race-inspired look that stands out from typical rear exhaust configurations.

However, side exit exhaust systems also require careful planning to avoid issues such as exhaust fumes entering the cabin or excessive noise. Proper installation and insulation are key to ensuring safety and comfort.

Tools and Materials Needed

Having the right tools and materials on hand is critical for a smooth installation process. Below is a detailed list of what you will need:

  • Socket set and wrenches: Various sizes to fit clamps, bolts, and hangers.
  • Jack and jack stands: To lift and safely support your vehicle while working underneath.
  • Rubber mallet: Useful for gently tapping components into place without causing damage.
  • Exhaust clamps and hangers: To secure the exhaust pipes and prevent vibrations.
  • Cutting tool (angle grinder or reciprocating saw): May be needed for trimming existing pipes or fitting new components.
  • Custom side exit pipes: Choose pipes compatible with your vehicle’s make and model or have them custom fabricated.
  • High-temperature exhaust sealant or paste: For sealing joints and preventing leaks.
  • Protective gloves and safety glasses: Essential for personal safety during cutting and handling hot or sharp parts.
  • Measuring tape and marker: To mark precise cutting and mounting points.
  • WD-40 or penetrating oil: Helpful for loosening rusted bolts and nuts.
  • Heat shield or exhaust wrap (optional): To protect nearby components and reduce heat transfer.

Preparation Steps

Proper preparation is vital to ensure safety and efficiency during installation. Follow these steps before starting:

  • Park on a Level Surface: Choose a flat, stable area such as a garage or driveway. This prevents the vehicle from shifting during work.
  • Engage Parking Brake and Chock Wheels: Always set the parking brake and place wheel chocks behind the tires to avoid any accidental movement.
  • Lift and Secure the Vehicle: Use a hydraulic jack to raise the vehicle and position jack stands under the frame or designated lift points. Never rely on the jack alone to support the car.
  • Wear Safety Gear: Put on gloves, safety glasses, and suitable clothing to protect yourself from sharp edges, hot surfaces, and debris.
  • Allow the Exhaust to Cool: If the vehicle was recently driven, wait for the exhaust system to cool completely to avoid burns.
  • Gather All Tools and Materials: Arrange everything nearby to streamline the workflow.

Removing the Old Exhaust System

Carefully removing the existing exhaust is the next step. This process requires patience, especially if bolts or clamps are rusted or seized. Follow these detailed instructions:

  • Locate Exhaust Components: Crawl under the vehicle and identify the exhaust pipes, muffler, catalytic converter, hangers, and clamps you will be removing.
  • Apply Penetrating Oil: Spray rusted bolts and clamps with WD-40 or a similar product. Let it soak for 10-15 minutes to loosen corrosion.
  • Loosen Clamps and Bolts: Using the appropriate socket or wrench, carefully loosen and remove bolts connecting the exhaust sections. Keep track of hardware for potential reuse.
  • Detach Exhaust Hangers: Use a pry bar or exhaust hanger removal tool to slide the rubber hangers off the mounting points. This step may require some force but avoid damaging hangers if you plan to reuse them.
  • Cut Pipes if Necessary: If your old exhaust is welded or difficult to remove as one piece, carefully cut through the pipes at accessible points using an angle grinder or reciprocating saw. Always wear eye and ear protection when cutting.
  • Remove Exhaust Components: Once all fasteners and hangers are freed, gently lower and remove the old exhaust system. Assistance may be needed for heavier components.
  • Inspect Mounting Points and Surrounding Areas: Check for rust, damage, or debris and clean as needed to prepare for the new installation.

Planning the Side Exit Pipe Placement

Before installing your new side exit pipes, proper planning and measurements are essential to ensure fitment, safety, and aesthetics:

  • Determine Exit Location: Decide exactly where along the vehicle’s side you want the exhaust to exit. Common locations are just ahead of the rear wheels or beneath the rocker panels.
  • Check Clearance: Measure the distance from the pipe exit point to the ground, body panels, and suspension components to avoid contact or heat damage.
  • Consider Heat Shielding: If the pipes will be near sensitive parts such as fuel lines, brake components, or plastic trim, plan to install heat shields or wrap the pipes with exhaust insulation.
  • Mark Cutting Points: Use a marker to outline where existing pipes will be cut or where new pipes will be mounted.
  • Test Fit the Pipes: Hold the side exit pipes in position to verify alignment with the exhaust manifold or mid-pipe and confirm the exit angles.

Installing the Custom Side Exit Pipes

With preparation complete, you can now proceed to install the custom side exit exhaust pipes. Follow these detailed steps to ensure a secure and leak-free installation:

  • Dry Fit All Components: Temporarily assemble the entire exhaust system without clamps or welding to check fitment and alignment. Adjust as necessary.
  • Cut Existing Pipes as Needed: Using your marked lines, carefully cut the original exhaust pipes where the side exit pipes will connect.
  • Attach Side Exit Pipes: Slide the custom side exit pipes onto the existing exhaust piping or connect to the mid-pipe using provided adapters or couplers.
  • Apply Exhaust Sealant: To prevent leaks, apply a thin layer of high-temperature exhaust sealant to the pipe joints before securing them.
  • Secure Pipes with Clamps: Position exhaust clamps over the joints and tighten evenly. Avoid over-tightening to prevent damage to pipes or clamps.
  • Reinstall Exhaust Hangers: Attach the rubber hangers to support the new pipes and minimize vibration. Replace worn or damaged hangers as needed.
  • Check Pipe Clearance: Ensure the side exit pipes have adequate clearance from the ground, tires, and body panels. Adjust hangers or pipe angle slightly if necessary.
  • Consider Welding (Optional): For a permanent and leak-proof installation, welding the joints is recommended. This requires welding equipment and expertise or the assistance of a professional exhaust shop.

Adjustments and Final Checks

Once the exhaust system is installed, meticulous final checks are essential to confirm everything is functioning correctly and safely:

  • Inspect for Leaks: Start the engine and listen carefully for any exhaust leaks, which often sound like hissing or popping near joints. Use a soapy water spray on joints to detect escaping gases by bubbling.
  • Check Pipe Alignment and Movement: Observe the exhaust while the engine is running to ensure pipes do not contact the vehicle’s body or suspension components during vibrations or suspension travel.
  • Tighten Clamps and Hangers: After a short test drive, recheck and retighten all clamps and hangers to compensate for any settling or movement.
  • Verify Exhaust Exit Direction: Confirm that exhaust gases are directed away from the vehicle body and any areas where fumes could enter the cabin or affect pedestrians.
  • Examine Heat Shields: Ensure heat shields or exhaust wraps are properly installed to protect nearby components from excessive heat.

Safety Tips and Maintenance for Side Exit Exhausts

Proper maintenance and safety precautions will prolong the life of your custom side exit exhaust system and ensure safe operation:

  • Wear Protective Gear During Installation: Gloves, eye protection, and durable clothing protect against burns, cuts, and debris.
  • Regularly Inspect for Corrosion and Damage: Side exit pipes are more exposed to road debris, water, and salt, increasing the risk of rust. Clean and inspect pipes periodically.
  • Check for Loose Fittings: Vibrations can loosen clamps and hangers over time. Tighten any loose components promptly.
  • Monitor Exhaust Noise Levels: Side exit pipes can be louder than stock. Ensure your exhaust complies with local noise ordinances to avoid fines.
  • Keep Exit Area Clear: Remove debris or mud buildup near the exit pipes to prevent blockages or damage.
  • Be Cautious Around Pedestrians: Side exit exhausts can emit hot gases closer to vehicle sides. Alert passengers and pedestrians to avoid burns or injury.
  • Professional Servicing: For welding repairs or complex adjustments, seek assistance from a qualified exhaust technician.

Common Challenges and Troubleshooting

Installing a custom side exit exhaust system may present some challenges. Here are common issues and solutions to help you troubleshoot:

  • Exhaust Leaks: Caused by poor sealing or loose clamps. Apply exhaust sealant and tighten clamps or consider welding joints.
  • Rattling or Vibrations: Often due to loose hangers or contact with body panels. Tighten hangers and add rubber isolators if needed.
  • Insufficient Clearance: Pipes rubbing against tires or suspension parts can cause damage. Adjust pipe angles or reposition hangers.
  • Excessive Noise: If noise is too loud, consider adding additional mufflers or resonators compatible with side exit systems.
  • Fumes Entering Cabin: Make sure exhaust exit is positioned well away from door seals and ventilation intakes. Adding door seals or deflectors may help.

Customizing Your Side Exit Exhaust System

Beyond basic installation, there are several ways to personalize and enhance your custom side exit exhaust system:

  • Choose Pipe Material: Stainless steel offers superior corrosion resistance and a polished finish, while mild steel is more affordable but prone to rust.
  • Select Exhaust Tips: Tips come in various shapes and finishes (chrome, black, titanium) and can dramatically change the look of your exhaust.
  • Add Sound Enhancers: Resonators or mufflers can be integrated to tailor the exhaust tone to your preference.
  • Incorporate Heat Wraps or Shields: These not only protect components but can also add a race-inspired aesthetic.
  • Install Valves or Cutouts: Electronic or manual exhaust valves allow you to adjust sound and flow on demand.

Conclusion

Installing a custom exhaust system with side exit pipes can significantly improve your vehicle’s performance, sound, and style. While the process requires careful planning, proper tools, and attention to detail, following this comprehensive guide will help you achieve a professional-quality installation. Remember to prioritize safety at every step, maintain your exhaust system regularly, and enjoy the unique benefits of your side exit exhaust setup.