Saab 9-3 Aero TTiD exhaust tailpipe replacement

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Thread: Saab 9-3 Aero TTiD exhaust tailpipe replacement

  1. #1
    Saab Newbie
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    Saab 9-3 Aero TTiD exhaust tailpipe replacement

    I’ve recently joined and thought my current modification is ongoing and might be of interest.


    Since buying my 9-3 the tailpipes have been a problem as the plated finish has become pitted. I couldn’t justify a new stainless exhaust, especially as the only one I liked the look of was the Hirsch system! Instead I’ve persuaded a friend of mine to see if he can fit two new stainless steel tailpipes. This is not the normal line of work he would undertake as he specialises in high end exhaust manufacture for race cars and classics - but I twisted his arm!


    The tailpipes I have chosen are 4” - bigger than the standard 3.5” and angled so they follow the line of the bumper when viewed from above (as per the original).


    Once the old tailpipes are removed you can see that the old exhaust pipes are flared at the ends to match the inner bore of the tailpipe ‘cans’…



    Clearly, this flare won’t be large enough for the new bigger stainless tailpipes to line up with, so he designed an adaptor. We were both keen that the reduction down to the original exhaust pipe size be as gradual as possible to prevent that 45 degree bevel look that you sometimes see…



    This can then be flattened to create a template…



    Using this template the adaptor can be cut out, rolled and welded together.


    Hope this is of interest, more details soon.

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  3. #2

    Re: Saab 9-3 Aero TTiD exhaust tailpipe replacement

    Cool, how did you remove the old tips? just grind them off?

  4. #3
    Saab Newbie
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    Re: Saab 9-3 Aero TTiD exhaust tailpipe replacement

    Quote Originally Posted by c2kev View Post
    Cool, how did you remove the old tips? just grind them off?
    Yes, just a couple of spot welds. Once the old tailpipes were off they have cut away the existing flared section of pipe and then welded the adaptors on. The new tailpipes will then be tack welded on as per the original ones. I'm hoping they will send some more pics to illustrate this better. Picking the car up tonight in any case.

  5. #4
    Saab Newbie
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    Re: Saab 9-3 Aero TTiD exhaust tailpipe replacement

    Some quick finished pics. It was getting dark and they are only taken on my phone. I’ll get some more done properly at the Saab meet at Castle Combe on Saturday when the car is clean. They are just what I wanted. My wife didn’t notice the change so they must look original!




  6. #5

    Re: Saab 9-3 Aero TTiD exhaust tailpipe replacement

    Looks a nice job, I got the same done to my car jut after I got it, only difference I removed the 2 boxes as well for a better flow, tips look the same on here:






  7. #6

    Re: Saab 9-3 Aero TTiD exhaust tailpipe replacement

    Both look amazing, I still have the standard tips on mine but will get there eventually


  8. #7

    Re: Saab 9-3 Aero TTiD exhaust tailpipe replacement

    No no no you need something like I've got image.jpg
    MSD REGISTER 26101 NOCTURNO-BLAU-MET

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