So How Does It Sound?
Go to www.popularhotrodding.com and check out the video of Project Nova as we put the new Hooker/Flowmaster system through a thorough sound check!

DIY vs. A Good Shop
We opted to use the services of Automotive Excellence in Huntington Beach, California, but assembling a custom exhaust system like ours is well within the reach of the average guy, provided you’ve got the right tools. Assuming you already have a serviceable MIG welder, a compressor, jackstands, and all the normal stuff, you can expect to buy a few specialty tools for a job like this. We priced out some super affordable tools from the DIY experts at Harbor Freight that will provide similar functions to the pro tools at AE. The comparison works out like this: AE charges about $300 in labor for a job like this. You get to watch from the sidelines while the pros do it, but you won’t gain much personal experience. Buying the tools yourself, however, will give you the satisfaction of doing it yourself, while rounding out your tool collection.

Exhaust System Sizing
It’s possible to mathematically calculate the flow requirements of an exhaust system based on the total mass flow of the system (mass of the ingested air plus the mass of the fuel), but it works out to about 2.2 cfm per engine horsepower. For a straight piece of round pipe, each square inch of cross-sectional area flows about 115 cfm, so it’s a matter of working forward from there. This handy chart takes most of the math out of sizing an exhaust system, and from this you can see that our 532hp Dart small-block breathes nicely with a dual 3-inch system.

PIPE DIA.: PIPE AREA (IN2): TOTAL CFM MAX HPPER PIPE: MAX HP(DUAL SYSTEM)
1.48 171 78 155
1⅝ 1.77 203 92 185
2.07 239 108 217
2 2.76 318 144 289
3.55 408 185 371
4.43 509 232 463
5.41 622 283 566

Tools You’ll Need
Description: Source: PN: Price
16-ton Central Hydraulics pipe bender, 3-inch capacity Harbor Freight 35336 $169.99
Chicago Electric heavy-duty cutoff saw, 14-inch blade Harbor Freight 91938 $69.99
U.S. General large tailpipe expander Harbor Freight 37354 $14.99
Total: $254.97

Where The Money Went

Item: Source: PN: Price:
U-Fit Dual 3-inch pipe kit Flowmaster/Summit 15937 $259.95
Super 40 Series Delta, 3-inch inlet/outlet Flowmaster/Summit 953049 $89.95 ea.
Super Comp headers, 17/8-inch dia. Hooker/Summit 2207-1HKR $755.95
Southern exhaust hangars AE/Nickson FW 913L $2.50 ea.
Total: $1,200.80

SOURCE
Automotive Excellence
714-841-1285
www.AutoExcellenceOnline.com
HarborFreight
3491 Mission Oaks Blvd
Camarillo
CA  93011
800-444-3353
www.harborfreight.com
Hooker Headers
704 Highway 25 South
Aberdeen
MS  39730
662-369-6153
http://www.hookerheaders.com
Miller Electric
1635 W. Spencer Street
Appleton
WI  54912
920-734-9821
http://www.millerwelds.com
Flowmaster Inc.
100 Stony Point Road
Suite 125
Santa Rosa
CA  95401
800-544-4761
http://www.flowmastermufflers.co
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G Force Crossmembers
330-753-5300
www.Crossmembers.com