We recently tackled a project to develop a new exhaust system for the Ford F150, opting for a design that integrates seamlessly with the existing OEM tubing rather than a bolt-on flange solution which would necessitate removing the factory resonator. Our choice to use a slip-fit design meant overcoming challenges with our equipment’s capabilities — specifically, accurately reducing stainless 3” tubing to 2 ¾” O.D. This precision was crucial to avoid installation and sealing difficulties for our customers.
Exhaust Tubing I.O. (inside-outside) End Forming Machine
Initially, our most cost-effective option seemed to be a Huth machine known for its swaging capabilities. While adequate for small-scale productions and typical exhaust shop uses, these machines fall short for high-speed, large-scale, and repeatable manufacturing processes. To meet our needs for efficiency and precision, we turned to an Inside-Outside (I.O.) machine, a tool at the forefront of industrial automation.
I.O. machines represent a significant leap in manufacturing technology. These machines are computer-controlled and fully programmable, allowing for adjustments across a variety of sizes and configurations. The machine we invested in is notably expensive, reflecting its robust industrial capabilities and alignment with the standards used by original equipment manufacturers (OEMs). The high cost extends to the tooling, necessary for producing diverse components like ball ends and expansion joints.
Exhaust Tube Forming Tooling
Operating an I.O. machine is straightforward but technologically advanced: an operator places the tube inside the machine, and the process kicks off automatically. It features an internal mandrel that expands to adjust jaws inside the tube, while an external mandrel simultaneously retracts to adjust the outer jaws, ensuring precise control of both the tube’s inner and outer dimensions. This dual control system is critical for achieving a high-precision fit, a stark contrast to simpler machines that only expand or contract tubes from one side.
This Is What It Takes To Make Exhaust Tips That Bolt On Just Like The Factory Ones.
The integration of such advanced machinery into our production line not only enhances the precision of our manufacturing processes but also exemplifies the broader benefits of digital automation in industrial settings. These benefits include enhanced product accuracy and quality, reduced costs by eliminating traditional analog components, and improved operational efficiency.
O.E Quality Fitment For Easy Installation With No Leaks
Our state-of-the-art I.O. machine represents our commitment to excellence, setting a new benchmark for quality in the aftermarket industry. It not only allows us to exceed industry standards but also demonstrates our unwavering dedication to crafting the finest automotive exhaust systems and accessories available.
