Custom Stainless Exhaust for a 1993 Mercedes G-Wagon

This G-Wagon came into our Brookvale mechanic workshop because the original exhaust was rusted out and replacement parts are no longer available. The goal was to build something that would fit right, last properly, and sound good without being over the top.

I built a 2-inch twin system that merges through an X-pipe into a single 2.5-inch section, all mandrel-bent and TIG-welded from 304 stainless steel. The X-pipe helps balance the flow between each of the engine pipes, which improves how the engine breathes and gives a smoother, cleaner note.

It is a V-band system from front to back, so there are no flanges or gaskets anywhere. V-bands keep things lined up better and make the whole system easier to remove later if it ever needs to come off. Everything was kept tucked up neatly under the chassis to keep the ground clearance that these G-Wagons need.

Fabrication Details

This was a full custom job, built from straight stainless sections rather than off-the-shelf parts. Every bend was measured, cut, tacked, checked for fit, and then welded out. The TIG welding is full penetration throughout. Apart from that, most of the work was done with hand tools and general fabrication gear.

There were about 20 hours in the build by the time it was done. As always, there were a few challenges along the way, mostly getting everything to line up cleanly around the chassis and drivetrain. Mounts and hangers were made to suit, using the factory positions where possible, and reinforced with stainless rod to stop them from fatiguing later on.

The whole setup was designed for sound and performance. It pulls exhaust gases through more efficiently and gives the engine a deeper, more balanced note. Nothing loud or harsh, just a proper tone that suits the vehicle.

Result

The G-Wagon is a daily driver, so the idea was to make something durable that still feels special. It now has a solid stainless system that should last longer than the rest of the car. The sound is deep and tidy, with no rasp or drone, and the flow is a clear step up from the old setup.

Jobs like this are part of keeping these older Mercedes vehicles on the road. Parts are getting harder to find, so sometimes the best option is to build them properly from scratch.

If a similar job came up again, I would need to inspect the vehicle first before taking it on. Lead time would be around two to three weeks, depending on the workload, and pricing would be by the hour, since every system like this takes as long as it takes.