1966 Chevy Nova Exhaust Buildup - Burns Stainless Steel Exhaust Components

1966 Chevy Nova Exhaust Buildup LS2 Engine

It's been a long time since your heard about Project Getaway, NHRA Pro Stock Motorcycle racer Ed Krawiec's '66 Nova, but unfortunately no matter how many resources we may have at our disposal, everyday life sometimes gets in the way of our projects. Nonetheless, we are putting the past in our rearview mirror and moving forward with a mission-completion!

We last left the Deuce with a custom-built firewall and rollcage courtesy of Carroll's Rod and Racecraft, which recently relocated to Englishtown, New Jersey. Additional modifications are to include finishing touches to the frame, customizing all mounting points for the Turn Key Engine Supply-built, Kenne Bell-blown LS2, and TCI 4L80E transmission, along with the flooring and tin work. With the engine and transmission shoehorned within the framerails, however, construction of the exhaust system was next on the chopping block. Considering Project Getaway will see duty as a g-machine, strip slayer and weekend warrior, it was a no-brainer that top-of-the-line exhaust components were needed for performance, ground clearance and, of course, the ultimate in aesthetics.

For this step, the good folks at Burns Stainless Exhaust in Costa Mesa, California, were willing to come aboard Project Getaway, supplying us with some of the finest, most technologically-advanced exhaust components available. Not only are we gaining a custom-built exhaust system capable of squeezing out every bit of available power, but we've also gained a wealth of information in exhaust technology, functionality of metals used, and how specific shapes and sizing can help or hurt a particular application.

Stainless steel has been chosen as the metal of choice to construct the entire exhaust system. As many of you may already know, stainless steel has excellent properties in warding off rust due to its high chromium content, but there is an additional benefit that swayed our decision. Stainless steel, compared to mild steel, has superior strength for use in high-temperature applications (such as endured by exhaust headers). Mild steel would not be able to withstand the constant high temperature heat cycles of our blown mill, while retaining its rigidity and premium looks.

In order to aid consumers in obtaining the proper components for their application, Burns has you fill out a Race Engine Specification Form (available at www.burnsstainless.com). This form is utilized to collect various information such as, but not limited to, peak rpm, horsepower and torque ranges, compression ratio, bore, stroke, engine displacement, camshaft and cylinder head specifications, and header configuration. Beyond submittal of the form, Burns will enter it into its X-design parametric exhaust system modeling computer program. Once processed, Burns can give you the optimum exhaust configuration to fit your needs, such as primary header tube diameter, length, if a step header is required (a larger size secondary tube welded to the primary tube), merge collector design and length, along with muffler design and length (if required for your particular application).

Pictured are the Gen-3 LS round tube, 3⁄8-inch thick, CNC-machined header flanges. These flanges are constructed from 304-stainless steel and are necessary to get the project started.
Pictured are the Gen-3 LS round tube, 3⁄8-inch thick, CNC-machined header flanges. These f
Bob Carroll begins by covering the exhaust ports with tape and bolting the flanges in place. The tape not only helps keep foreign matter from entering the ports, but also aids in judging the depth of the primary tubes to be inserted.
Bob Carroll begins by covering the exhaust ports with tape and bolting the flanges in plac
Next, Bob determines how much room is available between the engine, framerail, and control arm bulkhead before making the first cut. Once the stainless steel 17⁄8-inch primary tubes are cut, they are cleaned up and beveled via a belt sander. Before TIG welding can commence it is imperative that a shield be applied to the backside of the weld to prevent sugaring (oxides that are crusty in appearance).
Next, Bob determines how much room is available between the engine, framerail, and control

Solar Flux type B is utilized to form a crystallized barrier when heated, preventing oxygen from contaminating the weld.
Solar Flux type B is utilized to form a crystallized barrier when heated, preventing oxyge
After all tubes are mocked in place, they are held in via a small tack weld. It is important not to perform the final welding process until the entire system is constructed and proper fitment is achieved. Beyond the 17⁄8-inch primary tubes (which were all cut to 10 inches in length, as per the X-design software),
After all tubes are mocked in place, they are held in via a small tack weld. It is importa
Bob utilized a 2-inch secondary tube, better known as a step header. The step header design allows for better scavenging, thus improving the torque curve. Each tube is cut via a band saw.
Bob utilized a 2-inch secondary tube, better known as a step header. The step header desig

When considering exhaust speed or backpressure, it is extremely important to have a properly modeled exhaust system. Too much backpressure (a more restrictive exhaust) can be detrimental to top end power and harm the overall power curve, while the opposite (not enough backpressure) can cause an excessive peak in the power curve, hurting low-end torque and overall performance. This is a fairly basic principal that is often overlooked, so beyond spending big dollars on your powerplant, be sure to carefully choose the proper exhaust system size and design for you ride. Let's delve into the Burns Stainless components used on Getaway, the reasons why, and the exhaust construction process set forth by Carroll's Rod and Racecraft.

Pictured is the four-into-one merge collector, also made from 304 stainless and generally the most technologically advanced part of the exhaust system. The merge collector design contains four tubes into one; there is then a short section known as the transition and then the tail-ring. In extreme race applications, where open headers are run, this becomes a tunable part of the system.
Pictured is the four-into-one merge collector, also made from 304 stainless and generally
Different sized transitions can change torque and power bands. For example, a longer transition or megaphone can be used for maximum peak horsepower and broadened torque curve, while a shorter can be used to achieve the reverse. When utilizing a complete exhaust the effect is lessened. Notice the smoothness of all transitions within the collector, thus creating a balanced flow, while increasing horsepower.
Different sized transitions can change torque and power bands. For example, a longer trans
Next up, Bob will use the SS V-band clamps pictured...

...along with the SS transitions from 3.5 inches round to 3.5 inches oval tubing. The purpose of using the oval tubing is primarily for ground clearance—with the added benefit of looking great. Oval tubing does not provide anything as far as performance, but if sized properly it will not hurt either. If a larger oval is used above the required size of the standard round tube, it is a break even in performance at that point.
...along with the SS transitions from 3.5 inches round to 3.5 inches oval tubing. The purp
For a better view, here is the merge collector, V-band clamp and round to oval transition as an assembly.
For a better view, here is the merge collector, V-band clamp and round to oval transition
We can't wait to hear this baby purr!

Shown above are the 3.5-inch mandrel bent SS oval tubing sections available in many different angles.
Shown above are the 3.5-inch mandrel bent SS oval tubing sections available in many differ
Bob will incorporate an H-pipe into the exhaust system to help pull wasted exhaust gases away from the combustion chambers. An H-pipe allows the gas a different route to travel, thus helping achieve a balanced flow within both cylinder banks for increased horsepower.
Bob will incorporate an H-pipe into the exhaust system to help pull wasted exhaust gases a
Also pictured is Bob using a drill press with a hole saw attached to begin the opening in the oval tubing for the H-pipe crossover assembly to breathe.
Also pictured is Bob using a drill press with a hole saw attached to begin the opening in

Pictured here we have the Burns Ultra-Light stainless muffler assembly. These mufflers can be built to custom lengths and are available from 2- to 5-inch inside diameters. The Ultra-Light muffler contains a floating core design, allowing for easy rebuilds and as you can see has a straight-through design to provide the ultimate in flow, hence additional ponies.
Pictured here we have the Burns Ultra-Light stainless muffler assembly. These mufflers can
Also shown is the mid-section of the exhaust system neatly nestled beneath the Deuce.
In order to transfer the power to the pavement, TCI Transmissions hooked us up with a 4L80E. The 4L80E will provide the ultimate in strength and reliability, while providing us a fourth gear to save a little petrol. All TCI transmissions are triple tested to ensure superior function out of the box.
In order to transfer the power to the pavement, TCI Transmissions hooked us up with a 4L80

Pictured is the TCI unit installed behind our Kenne Bell-supercharged LS2, allowing us to properly construct the exhaust system.
Pictured is the TCI unit installed behind our Kenne Bell-supercharged LS2, allowing us to
Finally Bob TIG welds the back half of Getaway's exhaust system on a completely flat surface, guaranteeing that it is true.
Finally Bob TIG welds the back half of Getaway's exhaust system on a completely flat surfa
The oval tailpipe is nestled neatly below the rocker (between the door and the rear wheelwell), and will be trimmed to proper size upon final assembly. Bob will also box in the rocker and add a stainless steel trim ring to protect the paint—yes, that's right, Getaway will get some color very soon.
The oval tailpipe is nestled neatly below the rocker (between the door and the rear wheelw

Here we have the completed mock up. All seams will be meticulously welded via stainless wire and custom exhaust hangers will be added upon final assembly. In conclusion, as simple as we may think the exhaust system may be, there is a boatload of technology behind it.
Here we have the completed mock up. All seams will be meticulously welded via stainless wi

SOURCES
Turn Key Engine Supply 2620 Temple Heights Drive Oceanside CA 92056 760-941-2741 www.turnkeyengine.com	Carroll's Rod And Racecraft 11 American Way Suite 17 Spotswood NJ 08884 732-416-9887 www.rodandracecraft.com
TCI Transmissions 151 Industrial Drive Ashland MS 38603 888-776-9824 www.tciauto.com	Burns Stainless 1013 W. 18th Street Costa Mesa CA 92627 949-631-5120 www.burnsstainless.com