custom exhaust??

[reluctant]

newb here, must say...this forum is awesome!

i've read in the FAQ that uping the exhaust on my 1.6TD to 2.5" or 3" is one of the best upgrades that can be done.  I have a pile of scrap 3" stainless steel tubing where i work, and would like to use it on my turbo caddy project.  The only problem is that all the scrap is straight, no elbows, and I've looked into the cost of pre-made mandrel bends and $80 per bend is a little out of my price range.

My question is, if I were just to make all my bends by making angled cuts and welding back together, would all those sharp edges/corners reduce or cause flow problems? 

Would getting regular bend done at a muffler shop be an OK option?

and lastly, what would be a good muffler option?? or do i even need one?

thanks,
evan

[gnavs]

I would think regular bends would be better than angles, with mandrel bends being the best.  Have a look on ebay or http://www.mandrel-bends.com/catalog/mandrel-bends-34/409-stainless-steel-14-gauge-74/2-50-stainless-steel-409-3-75-radius-180-degree-mandrel-bend-675.html for cheaper mandrels.
2.5" should be fine, apparently 3" becomes a bit difficult to maneuver around things. 

[redneck_vdub]

I don't know much about idi's but I would not reccomend doing your exhaust with the angled cut dealy. The less angles there are the better. Try and get your bends done by an exhaust shop or if you have access to a bender, you can do it yourself. The muffler option is totally up to you, it just reduces noise.

That's just my 2 cents lol.

Colin