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After Market Exhaust Discs

I have been asked the question about making extra discs for the Boss.

I cut discs out of aluminum stock to test here but they are not for long term use.

http://forums.themustangsource.com/f813/experimenting-exhaust-discs-494329/

Update: As many know I have made many of these discs and still have them. Sizes are 1/2, 5/8, 3/4, 7/8 and 1 inch. One set shipped is $27 two or more just add $18 each, no extra shipping charges. Any questions please email me -- sjrsw (at) yahoo.com

Boss30270 on ebay

Installation instructions below

1/2

[youtube]http://www.youtube.com/watch?feature=player_detailpage&v=qO6KG_6zFts[/youtube][youtube]http://www.youtube.com/watch?feature=player_detailpage&v=7Lk26REE4Pw[/youtube][youtube]http://www.youtube.com/watch?feature=player_detailpage&v=a5T9p87vfPc[/youtube]
5/8

[youtube]http://www.youtube.com/watch?v=GF5sTzFabkQ[/youtube]

3/4

[youtube]http://www.youtube.com/watch?feature=player_detailpage&v=0MN1VW7cTZA[/youtube][youtube]http://www.youtube.com/watch?feature=player_detailpage&v=ifsPxZfO6no[/youtube]

7/8


[youtube]http://www.youtube.com/watch?feature=player_detailpage&v=tmZidzu5KXs[/youtube][youtube]http://www.youtube.com/watch?feature=player_detailpage&v=vdS6p9kX2bw[/youtube]
[youtube]http://www.youtube.com/watch?feature=player_detailpage&v=HN9KXmb9JmY[/youtube]

1 inch

[youtube]http://www.youtube.com/watch?v=8b4KKBJCFGM[/youtube][youtube]http://www.youtube.com/watch?v=iJYThQptsc4[/youtube]

Jack up the car as shown below, be careful not to put your arm in between the jack when reattaching the rocker bolt while underneath, it is easy to do and you see what I mean when doing it. If the piston ever gives way....

You will need to go just a bit forward from the jack point in the picture for the rear side pipes but that is fine, no damage worries. Just stay centered on the pinch weld, the rocker bolt is near the jack point in the picture. Otherwise loosen the rocker bolt before and after but that will make it a little harder to adjust. It is best to get a rubber pad for the jack, you can get them anywhere, I ordered one from harborfreight tools and it works great.

To install the Boss 302 exhaust discs you need a 15 wrench and a 15mm socket for the rocker bolts. You remove the three bolts/nuts circled, drop the pipe, pull out the old discs and install the new discs. Make sure the adjustment band on the side pipe has clearance from the floor or it will rattle. You will need about 3/8 of an inch or a little less then a finger width. This is made easier by first installing the rocker bolt but do not completely tighten it until you are finished adjusting the pipe.

If you are unable to get a good clearance with the floor or the pipe is not level (mine was not adjusted correctly from the factory) loosen the long bolt on the band and twist the pipe around a little, that will level the pipe and adjust clearance to the floor boards. As always email me with any questions.

discs2.jpg

Lifting points from the Ford service manual pdf
http://iihs.net/fsm/?dir=715&viewfile=Jacking and Lifting.pdf

Lifting points
JackPoints-2.jpg
Lifting points from the Ford service manual


Boss30270 on ebay
 
Re: After Market Discs

I'm in for a set of 1/2" and 3/4".
 
Re: After Market Discs

I should have some more info soon. I tried to make a set myself from stainless steel and it took a long time in the garage. While they would be useable I would rather have a nicer set made for the long run. The time I spend on these was not really worth the effort.
 
1,432
347
Re: After Market Discs

Water jet or laser would be the way to go IMO. I spent 4 years as a set up CNC machinist and yes you could crank them out that way. Water, laser, or plasma would be faster and easier I think. If you can make a CAD file send it to a water jet house and I'd guess the per piece price would be less than $4.

I'd send you some money for a set though. I think the best set would be a set of each size all in one bag.

Andy
 
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0
Re: After Market Discs

20 gauge can also be bunched easy enough with a Greenlee punch. It would be fine for making a few. But the cheapest way to make a bunch is with a CNC water jet, plasma, laser machine like Fat Boss said.
 
Re: After Market Discs

Posted this at Mustangsource also so please do not respond in both, thanks

OK, I spoke with Ford and was told they can be ordered at $15 each. I finally got a price on the ones I want to make at $9 each. I am going with these since they are stainless steel laser cut and they will have the bigger holes in them ready to go.

I will place an order in a couple of days for mine and anyone else that truly wants them, again this is not a business venture so I don't want/need extras. Figure US Mail anywhere from $3-5 and I would guess two sets would not make a big difference, so right around $25 at most but maybe less for a set shipped.

I am getting 3/4 and 7/8 cut and can have them made blank for 1/2, half is easy to drill out just use you original as a template. Drilling more then 1/2 is harder without the proper equipment. If there are a few that want one inch or bigger I guess that can be done, depends on how many.

Let me know soon.
 
Re: After Market Discs

Going to order tomorrow, roketman if you want them please reply again. Will check back to the thread in the morning after that I will be done with this.

Thanks


ALL DONE, No more
 
Re: After Market Discs

My discs arrived today and look terrific. A big thank you to Scott for putting this together. My plan is to give the discs to the dealer a couple of days before my Boss arrives and have them install them before I arrive to pick up the car. That way my wife thinks that exhaust sound is stock. ;) I can drill out or remove the discs from there.
 
Re: After Market Discs

5 DOT 0 said:
My discs arrived today and look terrific. A big thank you to Scott for putting this together. My plan is to give the discs to the dealer a couple of days before my Boss arrives and have them install them before I arrive to pick up the car. That way my wife thinks that exhaust sound is stock. ;) I can drill out or remove the discs from there.

Good Plan. ;) Now all you need is a car. ::)
 
Re: After Market Discs

Glad your happy, I am running my 7/8 now. Had a lot of people ask for them and sent out my set of 3/4 so I will have them run a second set. I guess I should make a few more spares since a lot of people are still asking for them.
 

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