How to Make Oval Exhaust Tubing: A Guide for Car Enthusiasts

To make oval exhaust tubing, you will need to use mandrel bending equipment and specialized tooling. With these tools, you can bend and form the tubing into the desired shape.

Oval exhaust tubing is a popular choice for automotive enthusiasts looking to modify their exhaust system. The unique shape of the tubing allows for increased ground clearance and reduced wind resistance compared to round tubing.

However, creating oval tubing can be a challenge without the proper equipment. Mandrel bending machines and specialized tooling are required to form the tubing into the desired shape while maintaining the integrity of the metal. In this article, we will explore the process of making oval exhaust tubing, including the necessary steps and tools involved.

How to Make Oval Exhaust Tubing: A Comprehensive Guide for Car Enthusiasts


Oval Exhaust Tubing: What It Is And Why It Matters

Exhaust tubing is an essential component of car engines, responsible for directing exhaust gases away from the engine. Oval exhaust tubing is gaining popularity due to its unique shape that offers more capacity for air and fuel to flow in and out efficiently.

This, in turn, enhances a car’s horsepower and reduces weight, providing better fuel efficiency. Oval exhaust tubing is particularly useful for high-performance vehicles like drag and race cars, which require improved aerodynamics to achieve high speeds. With its ability to increase engine power and reduce weight, oval exhaust tubing offers exceptional value for any car enthusiast or professional in the racing industry.

Preparing For Oval Exhaust Tubing Fabrication: Required Tools And Materials

To make oval exhaust tubing, you’ll need a few tools like cutting and welding equipment. Stainless steel and titanium grades are ideal materials to work with. Measuring and cutting tubing accurately to fit an existing system is important. Use tools like a mandrel bender and a pipe expander to achieve a better fit.

Sand the edges of the tubing to avoid scratches and maintain a smooth finish. Keep in mind that fabrication of oval exhaust tubing requires precision and patience. Make sure to take your time and work diligently.

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Fabricating Oval Exhaust Tubing: Step-By-Step Guide

  1. Design Your Oval Shape: Start by determining the dimensions of the oval shape you want for your exhaust tubing. This may involve creating a template or taking measurements if you have specific requirements.
  2. Prepare the Round Tubing: Cut the round tubing to the desired length using cutting tools. Ensure that the tubing is straight and free of any deformities.
  3. Set Up the Exhaust Pipe Bender: Place the round tubing into the exhaust pipe bender, making sure it’s securely held in place. Adjust the bender to the desired oval shape using your template or measurements as a guide.
  4. Bend the Tubing: Use the exhaust pipe bender to gradually bend the round tubing into the oval shape. Be careful to apply even pressure to avoid kinks or deformities in the tubing. It may take multiple passes to achieve the desired oval shape.
  5. Check the Shape: Periodically check the tubing against your template or measurements to ensure it’s taking on the correct oval shape. Make any necessary adjustments to the bender as needed.
  6. Cut and Weld (if necessary): If your exhaust system requires multiple pieces of oval tubing or if you need to join the oval tubing to other components, use cutting tools to trim the tubing as needed. Then, use welding equipment to join the pieces together securely.
  7. Test Fit: After shaping and assembling the oval tubing, test fit it in your exhaust system to ensure it fits correctly and aligns with other components.
  8. Final Adjustments: Make any final adjustments to the oval tubing as needed to ensure it fits perfectly and aligns with your exhaust system.
  9. Finish: If desired, you can finish the oval tubing with a suitable coating or finish to protect it from corrosion and enhance its appearance.

Please note that shaping exhaust tubing requires experience and precision. If you’re not confident in your ability to do this yourself, it’s recommended to seek the assistance of a professional exhaust system specialist or a metal fabricator who can create custom oval tubing to your specifications.


To sum up, making oval exhaust tubing is not an easy task, but with the right knowledge and equipment, anyone can do it themselves and save a lot of money. Whether you’re building a race car or restoring a classic car, there are many benefits to using oval tubing.

Before starting, make sure you have the right tools, including specialized clamps, mandrels, and benders. Take your time and follow the steps carefully, and you’ll end up with high-quality, custom-made oval tubes that will give your vehicle an impressive, unique look.

Additionally, using the correct tubing can improve exhaust flow, leading to better performance and sound. So why not give it a try and see the difference for yourself? With a bit of practice and patience, you’ll soon be a pro at making oval exhaust tubing!