I just finished quite the project this weekend... Installing / fabricating a Boss302 side pipe setup.
I started off with just the side pipes...


I did not however pick up the H-pipe that goes with it... I wanted to save a couple bucks and fabricate my own. Here is what I did.
I started by matching the shape of the mating flange, drilling 3/8" holes for bolts, and a pilot hole for the 2" pipe.


I then set up the 2" hole saw in the drill press and went to work. This took quite a while and a lot of cutting fluid to get through 5/16" of mild steel.



Now that the flanges were done, I needed to make the pipe. I picked up a mandrel-bent "U" of 2" OD stainless steel pipe from summit. The straight section needed to be about 2.5" long, and cut the bend at a 45-deg angle to mate up to the flanges.


I then dropped out the stock H-pipe and drilled out the sides of the pipe with the same 2" hole saw.


After a couple times of fitting under the car, welding the flange, the extensions were cut to length


Then, the final weld was made...


Right now, I am running them with no insert plates. On cold start-up they are quite loud. Once the car warms up though, they sound simply amazing. This is coupled with a set of GT500 mufflers out back, which I can barely hear anymore because of the sound coming out of the side pipes

 

Where did you pick up just the side pipes from and what did they cost you?

 

They can be ordered at the dealer as service parts.
CR33-5220-A (RH Pipe assy)
CR33-5220-B (LH pipe assy)
I got a great deal on craigslist for the pipes only, but you should be able to have your dealer order them for you.

 

Not coming up with any results for those part numbers at any Ford dealer part sources.

 

Looks good man! That's cool way of going about it! Got me thinking now!....

 

Impressive work Jason. I saw the video of it on YouTube, great sound!