I have been wanting to add a dual exhaust look to my cobalt, so I looked at body kits, and I decided that I like the stock look the best. So I thought I would make a dual cut-out, and make an exhaust cutout on the passenger side. Here is my how-to:

The first thing you want to do is remove the mesh screen from both sides of the bumper, and lay them back to back and mark with a sharpie what curve you want to cut. Then cut it slowly with a Dremel tool. Afterwards if you want, paint them Gloss black, because it will make them look fresher and stand out a little more. These are basically done at this point. That was the easy part!



Now mask off your bumper with some masking tape so you can draw where you want to cut. Measure the drivers side (it's about 6 1/2") And then draw a line on the passenger side where you want to cut.




Now disassemble your hack saw and put the blade face in and wrap it around the bumper. This will make it easier to cut. Now cut a straight line all the way through the bumper. Then repeat it on the other side of the cut (afterall you have to make two cuts.)






Once it is cut out, then use a file to smooth off the edges.

Now since the bumper is hollow I am picky and I wanted to fill it in so it would match the other side. I got some Plasticard and cut it out to match the bumper, and then superglued it to the bumper to cover up the gaps. If you cut straight then this will be easier!





Once the glue dries, use GM Factory touch-up paint. My car is Rally Yellow so I used The Factory Touch-up spray paint. GM Part Number 12346642. It works like magic. I have used it to repaint my front bumper after a spin out left it all scratched up. Note: The paint cans are only 5oz. plenty to do this job, but if you plan bigger projects like painting your interior, then buy a few cans.




Now reassemble the car by putting the bumper inserts back in, and use some double sided sticky tape to hold the passenger side on better, since it now only has one peg holding it in.



ENJOY!

 

Not bad

 

i see this must have been an all day event

when is the dual exhaust going on?

 

looks great,long day eh! what he said^^^whens the dual goin on

 

now all you need is a v8 and your set!

 

looks well done congrats

 

Nice work... Can't wait to see the duals.

 

I might put the Duals on this weekend. I will definitely post pics afterwards.

It wasn't so much an All day thing, I mostly just did a little at a time, because I as really tired. Some of the time was spent waiting for stuff to dry between steps. I'm thinking of going with 4" tips. Those stock 3" tips are kinda puny these days.

 

4in tips are the way to go! Looks good!

 

Here it is Completed FART CANS FTW!

 

Looks pretty good man. I wasn't sure I'd like the finished product, but am happily surprised. Any sound clips going up? I'd like to hear what she sounds like

 

looks very good. You took a risk on the cutting. But from what i know. I cant cross mine over to the other side.

 

how much for the extra exhaust?

 

Wow, that looks so ricey with those mufflers on there!!
I love the dual outlet look though, makes me want to do that to mine when I change the exhaust over the summer.

 

Every time i go to an exhaust shop they tell me that they cant put duals on my car. My cav was the same way. There is something real close to where the second pipe must run that has fuel stamped on it so noone wants to mess with it. What do i need to do to get duals put on? Just a heat shield?

 

These cars are ricey......just throwing one more grain in the bowl.



CGSS> The exhaust cost me $330......I orginally did not want mufflers and certainly no fart cans, but it sounds SO GOOD, well worth it. By far the best sounding SS I have ever heard.........and way better than that waspy sound it had before. You should hear it crack and rumble.



>Yeah it was risky, but way worth it....and how many else can say that they did it?

As for the exhaust, it is one pipe to the axle, and a y-pipe to split it. You cannot run two pipes over the axle, just not enough room, and going under tha axle is a dumb idea. So you can't have a true dual, but I did it for looks, and for sound......improved both dramatically. FART CANS FTW!

It actually sounds so good that you can rev it at a stop light and it actually rumbles instead of being all ricey sounding.....LOVE IT!

I think Gerber is going to be taking a video of them, no idea how good it will sound on video, but worth a try, especially if we can get a side by side comparison.

 

Gotta hear the sound. It looks so good I might do it.

 

I have been told that it sounds like and SRT-4 with 3" exhaust. I also thought is sounds like an SRT-4, especially the crackling when you down shift or let off the gas.

 

Well, I hope so. Thats the sound I want. What is the rest of your exhaust? header, dp and such. My exhaust cracks and burbles really nice already, but I love the SRT4 style sound and the dual exits. I gotta go bigger with my cat-back eventually, so I might as well do something like that.

 

F- the DP business. Just take your cat off, and go 2.5". I have not seen any reason for a 3" on these superchargers. Maybe if we had a bigger SC.

I removed my cat with a pry rod and a hammer.

Then did a 2.5" back from there, no resonator, and split it after the "axle". The mufflers are 2.5" inlet Wickedflow Fart cans.

 

Nice! Can't wait to hear it!.....Hey on your last exhaust when you bashed out your cat did you have a resonator?

 

Well, I got a 3" cat-less DP on there now. Thats why i'm gonna go 3" all the way back. The GMPP catback was the first mod I did before i got caught up in the modding frenzy.

 

Nope no Resonator, hence the loud whiny pitch it had.

 

Cool man congrats, looks good. Can't wait to hear it.

 

Do you think you can help me knock out all the crap in my cat?