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I'm building mine right now. $250 is a bit low for the parts, although it depends upon what size tubing your talking about. I've found 2.5" 180 degree mandrel bends for $25 a-la Jegs. 3" 180 degree bends are a different story though; the cheapest I've found is $75 each. I figure I'll need one 180 degree bend PER side to fab the down pipes…. test pipes can probably be done with a single bend and a bunch of straight, which by the way, is about $12-$14 per foot regardless of 2.5" or 3". The cat-back portion needs about 1 1/2 bends per side to build the X pipe and get everything to the mufflers. Don't forget the stainless plate needed to make the flanges which should be at least 5/16" thick, preferably 3/8" though. Mufflers? Lots of choices but hard to find a 304 stainless one for less than $100. I got a pair of Edelbrock's 3" center in/out but I can't stand the idea of single exhaust tips so I'm gonna cut them up so I can have dual 3" tips. Total: 6) 180 degree mandrel bends (3" $450) (2.5" $150)
2) Mufflers $200
6 feet straight tube $75
3/8 x 5 x 48 stainless plate (flanges) $60 No matter what, it's quite a bit less than the $2000 + you'd pay for an aftermarket kit. You could build it all out of mild steel for a bunch less, then watch it all rust away in a few years. Or you could pay about $400 to have it all ceramic coated but then you're back at the stainless price range. Hope this helps you a bit.... no matter what, it's always gonna be expensive.
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