Barra-Swapped XF Falcon Ute
Custom Exhaust & Intercooler Fabrication
The build
This Barra-swapped XF Falcon ute came into the Noizee Engineering workshop for the exhaust and intercooler side of the build.
We didn’t do the engine conversion on this one. The Barra was already in the car when it arrived, and our job was to build the supporting fabrication around the setup so everything could flow properly and work as it should.
With a 91mm turbo hanging off the side of it, this wasn’t exactly a standard street-car exhaust job.
what we fabricated
- 3.5” dump pipe
- Fabricated to suit the 91mm turbo
- Hypergate 45 wastegate setup
- Screamer pipe
- Custom intercooler pipework
- Built for a performance street car
Why the 3.5” Dump Pipe Matters
The dump pipe is the first section of exhaust coming off the turbo, so on a setup like this it needs to move a serious amount of gas without becoming a restriction.
A 91mm turbo is capable of pushing a lot of air through the engine. Once that air has done its job, the exhaust gases still need somewhere to go.
That’s why we built a 3.5” dump pipe rather than trying to choke the setup down with something too small.
It gives the turbo room to breathe and helps the exhaust side of the system work with the rest of the build rather than against it.
Hypergate 45 & Screamer Pipe
The XF is also running a Hypergate 45 external wastegate with a screamer pipe.
In simple terms, the wastegate controls boost by allowing some exhaust gas to bypass the turbo once the target boost pressure is reached.
The screamer pipe gives that bypassed exhaust its own exit instead of routing it back into the main exhaust system.
And yes, when it opens, you’re going to know about it.
For a performance-focused street car like this, it suits the personality of the build pretty well.
Project Details
- Vehicle: Ford XF Falcon Ute
- Engine: Barra swapped
- Application: Performance street carTurbo: 91mm
- Dump Pipe: 3.5”
- Wastegate: Hypergate 45
- Additional Fabrication: Screamer pipe and intercooler pipework
- Engine Conversion: Completed prior to arriving at Noizee
- Fabrication: Noizee Engineering, Hawkesbury NSW
Custom Intercooler Pipework
The exhaust side was only half of our job.
We also fabricated the intercooler pipework to suit the Barra and turbo setup.
Once the turbo compresses the intake air, that air needs to travel through the intercooler and back into the engine. The pipework needs to get it there efficiently without unnecessary joins, awkward routing or restrictions.
This is one of those parts of a turbo build that can look pretty simple once it’s finished.
That’s usually because someone spent the time making sure it actually fits properly.
Why Custom Fabrication?
You can buy a lot of parts off the shelf.
The problem starts when you try to make all those parts work together in a modified car that was never designed to run this combination in the first place.
A custom setup means the dump pipe, wastegate plumbing and intercooler pipework can be built around the actual car.
Around the turbo.
Around the engine bay.
Around everything else that’s already been modified.
That usually means better fitment, cleaner routing and a much better finished result than trying to piece together a system from parts that were designed for something else.
The Details
For the project gallery, show:
- 91mm turbo
- 3.5” dump pipe
- Hypergate 45 wastegate
- Screamer pipe
- Intercooler pipework
- TIG weld details
- Engine-bay fitment
- Pipe routing
- Finished fabrication
This is the sort of build where the close-up photos do a lot of the talking.
Built for the Street
This XF isn’t a dedicated race car.
It’s a performance street car, which makes the build even better in our opinion.
The goal wasn’t to create something that only works at the track. It needed a setup that could support the big turbo and performance side of the car while still being something the owner can actually enjoy on the road.
The combination of the 91mm turbo, 3.5” dump, external wastegate and custom intercooler pipework should make this thing a heap of fun once everything is finished.
We’re definitely keen to see it back on the road.
Building a Barra or Turbo Street Car?
If you’ve already got the engine and turbo setup sorted but need the exhaust, dump pipe, wastegate or intercooler fabrication to actually make it all work together, get in touch.
Tell Kris what you’re building, what’s already in the car and what you need fabricated.
We’ll work out the rest.
THE DETAILS
