this time when pedal box we begin the exhausting task of fitting our RIA silencer and designing all of our rear bumper supports now we're adding another manufacturer to the mix this is a Toyota gt86 back box and although we have got Subaru in already and technically the 86 is built in a Subaru Factory with a Subaru engine by Subaru engineers and then badged up with a Toyota badge we'll count it for the sake of what we want joining Porsche mg & VW Audi in the mix it's all going to do is build some extensions coming out the back of the chassis to around about here that we can mount the back box onto now I spent quite a lot of time on eBay looking for an appropriate box that we could easily pick off the shelf and this is the closest thing to it not very many have inlets on the top of the silencers and without building a completely custom box ourselves which is prohibitively expensive at this point this is as close as we can get it needs a small modification where this pipe is rotated round and that will allow us to go into the cat and then into the turbo now extensions themselves are going to come off the back of these chassis legs which have been open like this since about episode 6 which was more than two years ago at this point and will come further out to around about here and then we'll have a crash bar that goes across the back which we can remove if we need to take the engine off so that'll just be a bolt on bolt off piece but it means we can hang bodywork lights a number plates you know all those legally required things for a car on the road we have some of the same 80 millimeter box left over from when we did the rails back in episode 6 we're gonna cut this shape of the frame out at the end of this leg and then drop the front edge of it right up into there and weld the whole way along so that's and there we go to fit seamlessly onto the end of what's there we have to make a notch and take one side out where it contacts the suspension turret that will allow the extension to fit flush and seamlessly onto the rest of the car as we're welding smaller section box onto the end of this we've capped off the end to give all four sides of the new extension something to weld on to the first part of our new chassis extensions the back here is these these are basically the same 80 by 80 mil box that we had before we've cut a notch out the side this that actually fits over our suspension turret and we're gonna cap it off like that nice and easy now the next up we're gonna start extending out the back with a sixty by thirty box but we've got loads and loads of in the garage this is going to run out of here from the top right corner right here as far back as it needs to now to make sure that when this is taking any stress we're not bending this plate too much because the plate would be quite weak on its own we've put a little reinforcement gusset inside just resolve hold the plate out against any forces or this experiences we're going to build up this whole arm as far back as it has to go to clear the silencer which we're going to offer up now and just try and get a bit of a feeling for how far out this is gonna have to go [Music] once again our massive pile of clamps comes in handy and with a few pieces of scrap added in for good measure we can align the two pieces of 80 mil and 60 by 30 mil box to make sure they're exactly in parallel before they get joined forever [Music] [Music] here's one of our finished extensions the other ones already clamped on the other side ready to weld up but I'm just going to show you around what we've made here so that you've got a bit of an idea what we're doing we've got the horizontal flat bar going to come out the back which we're going to mount the rear bumper and everything onto this end goes up against the body the existing chassis that we've got and we've had to cut out the side to clearance around our suspension turret which actually comes into the width of our chassis arms so gonna throw these on weld them up and move on to the vertical supports to make sure it's aligned right we've run a piece of box section down the outside of the chassis as far as we can and clamped it to make sure it's okay that way and we're now gonna check the level where we've zeroed does this or a meter on a further forward part the chassis as we put this down hopefully it makes the noise it's not gonna make the noise there we go it made the noise it's been a while but weather's been kind of screwing us for a few weekends in a row no but we've got a bit of dry so we're gonna try and capitalize on that way we can now although we haven't finished welding these new extensions on fully in place we have had to prime them to try and keep some of the rain off but while we're working out today we could just go throw some new plates on we're gonna pop some little infill triangles on the back of the turrets to clean those up a bit I'm gonna put a nice reinforcing brace if I can remember which way round this fits on here just to give it a bit more vertical strength and hopefully stop it from swinging up and down so much as we start hanging the exhaust and everything else on the back here now that we've done the really important work of cosmetically cleaning up the backs our tires here we can move on to minor little details like actually hanging the exhaust to do that we've made up a couple of brackets this is a two-part bolt together bracket made of a piece of box section that we've cut down the middle and turned into a channel and we've put some holes through it that we can bolt into and we've then cut two faces off of a much thicker box section which we're going to use as the actual removable bracket so this part which is the one that you cut in half welds onto the side of the body here and then we bolt this section on and this top piece that we bolt on is going to contain the hangers that the exhaust is gonna hang on to while I was getting these welded in Adrian was turning down some pieces of metal rod that we could use in our hangars here so we've got little rubber hangers fairly standard one size fits all things we're gonna pop these through the rubber and then we're going to use some little half-inch box sections we didn't have enough of the rod for this we're just going to run that all the way from the hanger onto our bracket here so we're gonna get those welded up now [Music] here are the completed brackets we've designed them this way with the intention of putting them on the exhaust so the whole exhaust system is one assembly that we can then drop in complete just like this [Music] there's one more piece we need to add on to our extensions but we didn't put them in in case they got in the way of fabricating these as it turns out they wouldn't have but now we can put them in so this stay is going to come down from the top of the turret here and then we can prime all of this section back up again for about the seventh or eighth time to hang the rear bumper on the back of the car here we can do something quite similar to what we did with our brackets at the front we've got a couple of metal plates that we've bolted together and sandwiched up and we're going to weld these onto the back of our tubes though it's quite similar construction to the front end so you want to see a bit more detail on how this works check out the episode linked up in the corner but for now we're gonna charge right ahead with getting these welded on and the last thing we've added into this for a little bit of structural integrity and to make it look a bit nicer it's a small triangle of box just between the outside edge of this plate and the outside edge of our extension it just cleans up this area a little bit and it makes this plate especially where this bolt mounts a lot stronger it now doesn't Bend which was great when we were tweaking it back in line because it warped a little bit with the welding but really we don't want that to happen anymore we've put the box back in again and we can see exactly how it's sitting on the hangers now we've got the brackets done it's sitting a little bit forward so it's tipped like this at the moment and we might want to get some longer hangers later in order to just lower that down but right now we need to deal with this this is the inlet into the back box which at the moment inlets from right under here underneath the arm and there's no way we're going to be able to route that simply from there all the way around into the turbo over here so what we're gonna do is cut this right off at the edge of the box itself shorten this down about four or five inches and then reweld it on but we're also going to rotate it round to the top to give us a nice clear shot from there around back across and down into the box itself should be nice and simple and make our routing a lot easier to get to a custom exhaust would have been perfect but that's also expensive and modifying this one is both cheap and easy after a good deal of searching we pick this one up on eBay for fifty pounds which isn't too bad all told for a fairly simple solution to the problem at hand I've got this down to just its minimum radius and then put the bakbox back into the car again on its mounts and we can see how well this fits so this fits on here it's going to come straight about the top and you see there's plenty of room around here we can get tools in onto it which is a really nice bonus to be able to disconnect the exhaust with ease and we've got a much better shot across to our turbo over there so we're going to tack this in get that sorted and then when we come to do the rest of the exhaust just in case we need to tweak this around and redo any of the angles we'll weld it up then along with the cat and everything else [Music] thanks for watching subscribe to the channel like the video and comment it really does help us out remember we've got t-shirts available at shop pedal box show which will try and get posted out as soon as possible with the lockdown and if you go to patreon.com/scishow you can support us in our build because we're still working or at least I am because Kris is stuck at his parents the brackets for the exhaust turned out really well we're really happy with how they are and we've also got these extensions on which we've been looking to do for a while to try and work out exactly where the back of the car is gonna be so hopefully we're not going to extend this anymore we also got the inlet positioned and we can sort that out properly once we get the rest of the exhaust done and get that all welded up and sorted thanks very much for watching [Music] you
