This article will demonstrate how to splice in a stainless steel (hereafter "SS") Abbott Racing Motorsport 3" cat-back exhaust onto an existing 3" SS downpipe (hereafter "DP"), in this case an MP Performance DP. Materials required: A 1' section of 3" SS pipe, Vibrant SS V-band clamp, a large pipe cutter or steel saw, and a TIG welder with T-308 or 309 wire filler. The reasons for splicing in this manner are many. Both the DP and the exhaust have 3" to 2.5" reducers on the ends where they mate up. This mutual reduction creates a bottleneck just behind the cat. The exhaust could be mounted directly to the existing DP with a standard Saab clamp, but the bottleneck would then remain, defeating my ultimate goal of having a full 3" exhaust tract from the turbo, back.

First, I would like to extend my grateful thanks to those involved in the project:

Abbott Racing Motorsport for manufacturing an exhaust that fit perfectly. This was an absolutely no hassle drop-in, fit like a glove, 3" diameter stainless beauty of stunning quality. Jonethan (that is the correct spelling) Sepelak, a welder of consummate skill and artistry who is possessed of talent and the patience of Job. Tomy Turbo for the loan of his shop, a lift and numerous helpful tools. Mr. Fred Shaw of Shaw Saab, for exceptional customer service in efficiently arranging purchase and shipping to me of the exhaust in the first place. Mr. Shaw was instrumental in making this happen and I wish to thank him publicly for his extremely kind, fast and professional service. Our esteemed Administrator for providing this Forum and the Articles section in which to display the procedure.
 
This is the entire exhaust (edited low-res image from Abbott site - mine looked much prettier and shinier):
http://i27.photobucket.com/albums/c187/Saaboheme/AbbottExhaust/AbbottExhaust2.jpg

This is the rear section clamped into place just prior to test fitting:
http://i27.photobucket.com/albums/c187/Saaboheme/AbbottExhaust/Saab031.jpg

These are the two reducer ends (left from the MP Performance DP and right from the Abbott exhaust) after they were cut off to remove the bottleneck:
http://i27.photobucket.com/albums/c187/Saaboheme/AbbottExhaust/Saab040.jpg

Abbott exhaust with reducer cut off:
http://i27.photobucket.com/albums/c187/Saaboheme/AbbottExhaust/Saab030.jpg

This is the male half of the Vibrant SS V-band clamp welded onto the DP after the reducer end had been cut off:
http://i27.photobucket.com/albums/c187/Saaboheme/AbbottExhaust/Saab029.jpg

This is a view from beneath the polished center resonator showing the Abbott exhaust end ready to have the short (approximately 6" long) extension section welded on and with the male half of the SS V-band clamp tacked into place:
http://i27.photobucket.com/albums/c187/Saaboheme/AbbottExhaust/Saab032.jpg

Jonethan, welder extraordinaire, test fitting the short extension section to the Abbott exhaust (where it will ultimately be butt-welded into place). Note that the cut at the Abbott end had to be made a very slight angle to facilitate having the extension end meet up at the V-band clamp connection square enough to fit perfectly. There is a flex section immediately behind where the weld will occur which would allow enough movement to permit a straight cut, but the goal here was to relieve as much stress from the butt-weld as possible:
http://i27.photobucket.com/albums/c187/Saaboheme/AbbottExhaust/Saab033.jpg

This shows the center extension section welded into place, with the female end of the V-band clamp already welded on and the V-band clamp torqued down:
http://i27.photobucket.com/albums/c187/Saaboheme/AbbottExhaust/Saab035.jpg

Another view of the center section after fitting and welding:
http://i27.photobucket.com/albums/c187/Saaboheme/AbbottExhaust/Saab038.jpg

This is a close-up of the center section butt-weld:
http://i27.photobucket.com/albums/c187/Saaboheme/AbbottExhaust/Saab037.jpg

The rear section bolted into place after everything else was completed. The final fit was perfect:
http://i27.photobucket.com/albums/c187/Saaboheme/AbbottExhaust/Saab036.jpg


A final note (pun intended) on the exhaust:

The materials, build quality, fit and finish of the Abbott Racing Motorsport three inch stainless steel exhaust is uniformly excellent. It is patently obvious that this product has been designed and constructed to the highest standards. The welds are correct, true and strong, and the craftsmanship in their execution is beyond reproach.

Upon its receipt, I was torn as to whether to install it immediately, or to hang it on my living room wall, as it is simply too beautifully made to hide it beneath an automobile. It is, in a word, art. Abbott's exhaust is the perfect exemplar of the harmonious union of form and function.

The design of the exhaust proved to be perfect. Fitment of this exhaust was easier than installation of the stainless Saab Sport exhaust I had fitted previously. Each and every bend, union and hanger was exactly where it needed to be. No custom fabrication of clamps or hangers was necessary. Best of all, this exhaust delivers palpably superior performance with a quiet and mellow exhaust note. The throatier and raspier sound of the prior system had begun to lose its allure for me and I was very much hoping for a quieter and more civilised result from this exhaust. I am delighted to report that the Abbott exhaust has more than met my expectations in this regard. This single improvement has contributed immensely to my daily enjoyment of my convertible Saab.

Finally, I would be remiss should I fail to commend the people at Abbott for their world class customer service. I was fully informed about the status and progress of my order from its inception through its safe arrival at my door. Communication with Abbott via their American agent, Shaw Saab, was seamless and effortless. Abbott took great pains to ensure that they were providing the exact product I needed. I am unable to say that I have enjoyed a better and more satisfying purchasing experience than this one. My sincerest thanks to Abbott Racing Motorsport for its invaluable contributions to the Saab performance community.

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