Home made FAE fresh air exhaust?

[icemanftr]

Anyone tried to fab their own FAE out of pvc or abs? Hard to come up with the 5-600 for aftermarket and priced pipe out at Lowes and figured I could make one for about $25. Or even mock one up and go to exhaust shop and have one made out off SS pipe to match my mock.


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[mmandley]

Trayson made one and it didn't work out.

Issues you will run into is mounting to the platform. You have to get it mounted in the cross section or it will come off. Another concern in the down pipe. It can't be just a round pipe, too much drag and it week effect the waves.

I think you would be better to use metal piping and rubber connects with a similar downpipe.

Careful though because I think FAE is a patent item.

[mikenehrkorn]

Careful though because I think FAE is a patent item.

I think you are safe if its just for self use, but if you start trying to sell it to others that is another story.

[Fastest1]

All I know is mine is quiet!


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[sivs1]

I made one, love it.

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[jmvotto]

pictures please

[trayson]

Trayson made one and it didn't work out.

I made one for my Supra. my first generation model was held on with pipe strapping. I had a few issues:

1) I had the angles and the Z-length measurement wrong and it made a rooster tail that really messed with the wave
2) I had used heat to shape the PVC downpipe to a more narrow profile, but the heat of the exhaust combined with the force exerted on it actually warped my downpipe.
3) Because I had the wrong angles/length of some of my piping, one of the pieces of metal strapping didn't hold and the assembly started to come off the boat

None of these problems were insurmountable. And I'm not totally surprised that on my "Version 1" that it wasn't a slam dunk success. But like mentioned above, I had maybe $25 into it. While it was on and working, the sound benefit was AMAZING.

However, I ultimately sold that boat and moved on to my XLV. with a new boat, came a new list of projects and there were a ton of other things that took priority on my wish list over the homebrew FAE.

This winter I intend to tackle the project again and have sourced a lot of the parts already. On my Supra, I went with PVC because it's supposedly more resistant to UV rays, but on the XLV I intend on using ABS because it's thicker and because I think black looks better than white pipe.

Bottom line is that yeah, I'll make another one eventually, but other projects have taken priority for now.

[5:00]

One thing I noticed on the SS FAE is that the heat from the exhaust dissipates very quickly through the metal. I have checked it a couple of times just to see how hot it would be to the touch. I had to get almost to the exhaust outlet on the boat for it to be too hot to hold. Within 6" of the boat's exhaust it was cool to the touch. There is a huge amount of heat dissipation through the metal.
Hopefully the ABS will be able to stand up to moreheat being that it won't conduct much.

[sivs1]

I only have pics without the platform on.

I added a bar across the platform supports that then helps hold this in place. I also added screws into the exhaust pipes coming out of the boat with washers to help give the straps something to grab onto.

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[trayson]

So you went from the elbows right into the Tee? I didn't have quite enough width to use that Home depot Tee that you have pictured. I had to get a narrower tee and will have to have straight pipe between my elbows and the tee.

But I am going to be going down a similar path...

[sivs1]

So you went from the elbows right into the Tee? I didn't have quite enough width to use that Home depot Tee that you have pictured. I had to get a narrower tee and will have to have straight pipe between my elbows and the tee.

But I am going to be going down a similar path...

Yes, the black is basically sewer pipe and the grey is electrical.

[That Guy]

Hmm, and the plastic piping doesn't melt or anything?

Anyone made one for a single exhaust outlet? Any reason why I couldn't just make a 90* elbow straight down from the exhausT?

FAE is on my winter mods wishlist...never thought about making my own.

[trayson]

Hmm, and the plastic piping doesn't melt or anything?

Anyone made one for a single exhaust outlet? Any reason why I couldn't just make a 90* elbow straight down from the exhausT?

FAE is on my winter mods wishlist...never thought about making my own.

one of the key factors is having the downpipe of the exhaust go into the center of your prop wash. that will provide minimal disruption to your wake and speed. So even with a single outlet, you would need to have it go over to the center and output into the prop wash. Otherwise you'll have the equivalent of a big trim tab on one side if you simply do a downturn.

[gregski]

One thing I noticed on the SS FAE is that the heat from the exhaust dissipates very quickly through the metal. I have checked it a couple of times just to see how hot it would be to the touch. I had to get almost to the exhaust outlet on the boat for it to be too hot to hold. Within 6" of the boat's exhaust it was cool to the touch. There is a huge amount of heat dissipation through the metal.
Hopefully the ABS will be able to stand up to moreheat being that it won't conduct much.
That doesn't sound right. I can comfortably put my hand on the exhaust manifold. If never noticed anything in the water (behind the transom) that is hot.

[newty]

So you went from the elbows right into the Tee? I didn't have quite enough width to use that Home depot Tee that you have pictured. I had to get a narrower tee and will have to have straight pipe between my elbows and the tee.

But I am going to be going down a similar path...
Trayson, those aren't standard 90's. They are called street 90's. They take less space and one less joint.
Take a look and see if that type will fit.

Someone needs to try to use a pipe pvc pipe bender. It uses heat and you could use it to flatten the downpipe for less resistance, much like the GSA pipe shape.

Now get to modding!

[beat taco]

Vent 90's are the tight ones.

[beat taco]

Not that I condone what I'm seeing here.

[beat taco]

But yes a vent street 90 would work....

[newty]

Baby steps Jake, not too much at a time. 😁

[beat taco]

Baby steps Jake, not too much at a time. 😁
Maybe wrapped in vinyl bling it will look ok.

[newty]

YES! And some epoxy for strength!

[beat taco]

Epoxy is marine duct tape.

[mmandley]

That doesn't sound right. I can comfortably put my hand on the exhaust manifold. If never noticed anything in the water (behind the transom) that is hot.

I would caution that statement. I have seen plenty of steam from my boat and others in the PNW when water and air are over 65 when surfing.

Yes is not as hot as normal exhaust because of water being added but I wouldn't stick my hand behind my exhaust under load.

[gregski]

I would caution that statement. I have seen plenty of steam from my boat and others in the PNW when water and air are over 65 when surfing.

Yes is not as hot as normal exhaust because of water being added but I wouldn't stick my hand behind my exhaust under load.
That's two different things. That is condensation, like seeing your breath in cold air - that won't burn you. Have you never touched your exhaust manifold? It's toasty warm but not burn-you-hot. If it or the FAE pipes are hotter than that, you have a problem such as failing impeller or pump or some obstruction in the water flow.

[mmandley]

That's two different things. That is condensation, like seeing your breath in cold air - that won't burn you. Have you never touched your exhaust manifold? It's toasty warm but not burn-you-hot. If it or the FAE pipes are hotter than that, you have a problem such as failing impeller or pump or some obstruction in the water flow.

No I have not touched my exhaust manifolds, maybe I'll try your theory.

I am wondering why would FAE make the system out of Metal if they could have used a Plastic which would have been MUCH cheaper in overhead?

PVC begins to warp at 104c or 219F. Exhaust temps over 140 are more then hot enough to Burn you.

Those of you thinking you will try ABS might find it interesting that at 98c or 208F ABS begins to distort as well.

[kaneboats]

In FL my manifolds get hot enough to burn you. I can guarantee you that.

[icemanftr]

I only have pics without the platform on.

I added a bar across the platform supports that then helps hold this in place. I also added screws into the exhaust pipes coming out of the boat with washers to help give the straps something to grab onto.

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Looks pretty good and exactly what I had pictured in my head. Glad to see such a great response to this.

[gregski]

In FL my manifolds get hot enough to burn you. I can guarantee you that.
As I thought about this, it occurred to me that the manifold temperature would be directly related to the lake temperature; i.e. if your lake is 10 degrees warmer than mine, then your manifold is likely 10 degrees warmer than mine. Our lake never got above 70 this year, yours could have easily been 20 degrees warmer.

[trayson]

As I thought about this, it occurred to me that the manifold temperature would be directly related to the lake temperature; i.e. if your lake is 10 degrees warmer than mine, then your manifold is likely 10 degrees warmer than mine. Our lake never got above 70 this year, yours could have easily been 20 degrees warmer.

I would also think that on a boat equipped with a heater, that the manifolds would end up cooler too. Because the heater is essentially a "heat exchanger" or a radiator. so if the heater core from the heater is bleeding off heat from the engine, then by the time it gets to the manifolds it would be cooler than a boat not equipped with a heater... Seems logical anyway.

[gregski]

I would also think that on a boat equipped with a heater, that the manifolds would end up cooler too. Because the heater is essentially a "heat exchanger" or a radiator. so if the heater core from the heater is bleeding off heat from the engine, then by the time it gets to the manifolds it would be cooler than a boat not equipped with a heater... Seems logical anyway.
No, probably not. The heater taps off of the thermostat controlled water jacket. If the heater is on and taking some heat away from the motor, then the thermostat will just close off a bit of the incoming cold water. Basically that water temp is always 160 - or whatever your thermostat is. The exhaust side simply mixes the exhaust gas with a lot of cold raw water.

[trayson]

No, probably not. The heater taps off of the thermostat controlled water jacket. If the heater is on and taking some heat away from the motor, then the thermostat will just close off a bit of the incoming cold water. Basically that water temp is always 160 - or whatever your thermostat is. The exhaust side simply mixes the exhaust gas with a lot of cold raw water.

Yeah, that makes sense. You're right.

[icemanftr]

The lake temps in peak summer here vary from 75-83 degrees depending on which lake we go to. Average is probably 75. But we also have cold as winters so the warm water only lasts about 2 months. Lol


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[sivs1]

So as we're talking about Temps I can say after two seasons with my home made version pictured previously I have not seen any warping or concerns about high temps. I can say the two exhaust pipes coming out of the boat have warped slightly, basically where I put screws in to help hold the fae.

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[5:00]

We are in the heat zone in Northern Virginia where the water temps are 70F+ and the air is usually 85-95F. It does cool within inches of hitting the FAE. It sounds like it really may be water temp dependent and the materials on this mod may really make a difference depending on where you are. I am hypersensitive about heat after a close call when the strainer got clogged so I check the gauge about every 5-10 minutes. I check the components a lot also and the exhaust is normal for here.
ABS and PVC may work great up north but not down south. For the systems working short term it seems good but what will happen over the course of a season or two as it may become brittle with temperature cycles, freezing and time. If it lasts a couple of seasons you are way ahead of the game cost wise.

[mjr119]

We are in the heat zone in Northern Virginia where the water temps are 70F+ and the air is usually 85-95F. It does cool within inches of hitting the FAE. It sounds like it really may be water temp dependent and the materials on this mod may really make a difference depending on where you are. I am hypersensitive about heat after a close call when the strainer got clogged so I check the gauge about every 5-10 minutes. I check the components a lot also and the exhaust is normal for here.
ABS and PVC may work great up north but not down south. For the systems working short term it seems good but what will happen over the course of a season or two as it may become brittle with temperature cycles, freezing and time. If it lasts a couple of seasons you are way ahead of the game cost wise.

Only every 5-10 minutes??? You are boating rather carelessly now arent ya?? Haha mostly kidding. But no joke, I constantly watch my temp and oil pressure gauges when boating. Whether I am driving or not. Even when I am surfing! I'm goofy so I can see over the drivers right shoulder to check the temp gauge. Or if my wife is driving, I'll get her attention and ask her to confirm the boat's vitals are okay. Not sure if it's OCD or just paranoia haha. But I do it. I can't relax otherwise.

[5:00]

Too funny, I do the same thing. No matter who is driving I ask for the temp. I am in a whole different place now without the plant life that clogged it but it is an avoidable situation. Oil and temp gauges should really be front and center with a warning tone.

[mmandley]

Why don't you guys make your base design with abs or pvc then take it to an exhaust shop and pay for 3 inch pipe to be bent and welded. Then take it to a powder coat guy and get it done, or a chrome shop.

You get a solid unit, long term use, and it's all still under 200.

[bergermaister]

You get a solid unit, long term use, and it's all still under 200.

Yeah right! What exhaust shop are you going to?!

[beat taco]

Yeah right! What exhaust shop are you going to?!
Best prices in pdx: http://www.darrelsmufflersportland.com/

[mmandley]

Yeah right! What exhaust shop are you going to?!

Maybe I should ask what shop your going to. I did the exhaust on my Vette last year for 125. Maybe you need to work on your haggling. Cash works wonders when you say no recipe needed.

[bergermaister]

Local muffler guys around here apparently use 14ct welding wire and diamond studded tubing benders.

[DOCDRS]

Maybe I should ask what shop your going to. I did the exhaust on my Vette last year for 125. Maybe you need to work on your haggling. Cash works wonders when you say no recipe needed.

I never need the recipe, i just wing it

sorry mike had to

[trayson]

it might depend on what material you'd be having the exhaust shop use. I couldn't see using anything but stainless or aluminum because our pipes are going to spend a lot of their life submerged. I doubt that Mike's corvette pipes are stainless, as last time I checked, he wasn't floating around Hagg in his vette.

I priced a custom FAE made from Aluminum from a local fab shop here in Vancouver and it was prohibitively expensive.

[mmandley]

I never need the recipe, i just wing it

sorry mike had to

Touch'e

No I don't think my pipes on the Vette are SS.

But if your powder coating it isn't going to rust.

Just saying there is still other options

[Rgar]

Anyone have any pictures of how they are fastening the fae to the exhaust ports?

[mmandley]

FAE uses rubber sections to go between the steel pipe and plastic flange on the boat.

I use screws to attach the rubber to plastic. Then a band clap to keep the screws from backing out.


Just so the masses know, I didn't replace my entire exhaust on the Vette for 125 it's only from the rear axle back. But for an FAE you only need about 3-4ft of pipe. On the Vette I think they used 5-6 ft of pipe, then 4 welds to attach everything

[icemanftr]

I ended up with the real deal! Couldn't pass up a smoking deal on used one!!! Mocked up today. http://images.tapatalk-cdn.com/16/01/07/c6c887e4d9518bbf85b5ec81c55a97c1.jpghttp://images.tapatalk-cdn.com/16/01/07/94419938a79e25c01a34cd1dbc47c04f.jpg


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[MJHSupra]

Where did you find a used one? Craigslist? Local Shop?

[icemanftr]

Where did you find a used one? Craigslist? Local Shop?

Funny story. I posted on FAE Facebook inquiring on one last summer. A member had saw my post and had same boat as mine, which he sold and took FAE off before sale. So he contacted me by Facebook wondering I was still interested. I said of course and I paid less than half to my doorstep! Couldn't have gotten any luckier. http://images.tapatalk-cdn.com/16/01/12/b9386f560ebb9ec179addeb62f35c409.jpg


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[That Guy]

Jealous! I ordered mine on Black Friday and saved a bit but that much! Looks great.

[MJHSupra]

That's cool. Good for both of you. You got a great deal and he got a few more dollars in his pocket on a sold boat.


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[CRAZy440]

How are the FAE systems going to work with single exhaust like this:

http://cdn-9.psndealer.com/e2/dealersite/images/romoboco/vp4530587_9_large.jpg