Exhaust Pipe Size & Custom Exhaust Tips | Summit Racing Quick Flicks


Hi I am Mike and on this installment of Summit
Racing Quick Flicks we are going to discuss exhaust pipe sizing. When building a custom
exhaust system out of miscellaneous components it is important to understand how the industry
sizes different components that are going to be necessary to build that system. Exhaust
piping, mufflers, collector reducers all are going to be sized differently from one another
to ensure compatibility and to make sure they mate up with one another. What we are going
to discuss is the difference between the measurement of these items when it comes to OD in comparison
to ID and what components are going to go ahead and fit together with one another as
an end result. The first component we are going to discuss is in building one of these
systems is exhaust piping. Most exhaust piping is going to be measured using OD dimensions
which is outer dimensions of the pipe or the outer diameter. That means if you were to
purchase a three inch pipe let’s say like the one we have here the outside diameter
of this pipe would actually be three inches. This creates a situation to where this pipe
is then designed to be a slip fit or slip into a component that has a three inch inner
diameter. That will essentially create what is known as a lap joint between those two
components where one fits within the other component. This is important to understand
because sometimes you have to connect one pipe to another say from a collector reducer
over to the pipe itself. This creates a situation now where the two items cannot actually be
slipped in one another and it makes it not possible to have that lap joint like we mentioned
this is what is known as a butt joint instead. Exhaust system components such as mufflers
and exhaust tips normally use inner diameter dimensions on the piping used to build these
components most of the time this does create a lap joint fit when it comes to connecting
this pipes to these components in the system. The most common type connection when connecting
a piece of exhaust piping to a component such as a muffler is what is commonly known as
a lap joint connection which is essentially means that we are going to be able to insert
the pipe into to component as shown here. This type connection is probably easiest to
deal with as well because you can typically take a standard saddle clamp or the proper
band clamp and get these two connected to one another or you can just weld the seam
between the two as well for a leak less fit essentially. These will always have some measurable
leakage though if using a clamp to connect the two because what will happen is you will
always have that seam between the two components that is going to give it the ability to have
just a small amount of leakage between the two. The other type of connection used in
a system is what is known as a butt joint meaning that both components are going to
have the same outer dimensions as one another. Exhaust piping is a common area where you
are going to encounter this. This means that when you try to go connect the two pieces
you will notice that if gives you a seamless fit but at the same time you are going to
have trouble getting the two components connected to one another without the proper clamp or
being able to weld the two components together. This can prove to be difficult for the do
it yourselfer who doesn’t own a welder is at home in their own garage trying to build
a system independently of buying a preformed system specific to their vehicle. Here at
Summit Racing we carry a couple different clamp designs that are going to be used depending
on the type of joint you are trying to connect together. The first two we are going to be
focused on are lap joint connection clamps, first being the saddle clamp which we are
probably most used to seeing this clamp here is going to use a U shaped bolt essentially
and a saddle bottom which is basically going to crimp the two pieces of pipe together to
create the seal. We do have another option though which is what is known as a band clamp
and a lap joint band clamp is going to be evident because you are going to notice that
one side is going to be visibly larger than the other its literally going to taper meaning
that you have one pipe that is going to be fitting on the inside of another, these do
not clamp as much as they hold the two pipes stationary and create a full 100% seal via
this seam internally here. These being more desirable of the two clamp designs because
you don’t get any distortion of the pipe when they are connected together. In comparison
when connecting a butt joint connection your only option in the clamp world is going to
be to use a band clamp reason being is that a saddle clamp will not have enough meat to
connect the two with a saddle clamp design. If you look at the difference between the
two band clamps out there you will notice that lap joint has the tapered end on it whereas
the band clap used to connect the butt joint is going to be the same diameter throughout,
there is no tapered edge it’s the same internal diameter. This is a good solid way to connect
the butt joint but the best way to connect the butt joint is via welding. There is a
way also to go ahead and convert your butt joint over to a lap band joint, we sell this
tool here at Summit Racing Equipment this is a tubing expander that is basically going
to go ahead create the extra clearance internally inside the tube to make it so that whatever
component your trying to connect will now slip into the component that you are expanding.
This is a good option if you want to go ahead and use the saddle clamps as an end result
to build your system.

13 thoughts on “Exhaust Pipe Size & Custom Exhaust Tips | Summit Racing Quick Flicks

  • On a lap joint…what if you used a high temp silicone in the lap to seal the exhuast would there still be a leak?

  • If I'm trying to swap in a catless pipe for a cat, is the butt joint band clamp a viable option or will vibrations from driving loosen them?

  • Tried both. Butt connected pipe to muffler with a band clamp. Leaked horribly. Tried to expand a pipe to fit over a muffler. Expander split in the middle. No luck

  • If I have exhaust pipe with 2.50 OD would I get an exhaust tip with an inlet of 2.50" for it to slip over the pipe?

  • So, if I have a 2.5 OD can a 2.5 ID GO INSIDE THE 2.5 OD? Also if I have a 2.5 OD CONNECTING A 2.5 OD what size butt joint clamp would I need?

  • Hi awesome vid! Any fitting vids on those clamp? Also would the over lap joint work on the exhaust tips? What size would I need for the 2.25inch pipe? Thanks

  • sanavaa beeshhh 🤔😨😱so only at summit I can get this shhietT 🙇🙇🙆🙇🙆🙇🙆🙇🙆🙇🙆🙇🙆🙇🙆🙇🙆🙇🙆🙇🙆🙇🙆🙇🙆🙇🙆🙇

  • Informative.
    But let me guess….guy is from the Sales Department.
    (Wonder when he last got grease under his finger nails.)

    Very "salesy."

    Lol.

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