Exhaust Modeling and Detailing

1. Setting Up the Exhaust Box

• Create a box as the base.
• Align and position it relative to the scan data.
• Adjust dimensions to match reference images.

2. Adding Ridges to the Box

• Create 3 evenly spaced ridges:
  • Select edges → Connect (3 divisions).
  • Use Chamfer to create spacing.
  • Adjust width and extrude outward slightly.
• Scale inward slightly to mimic real-world ridges.

3. Cutting Out Exhaust Details

• Identify cylinder cutout and bolt holes.
• Create six rectangular cutouts:
  • Use array modifier for even spacing.
  • Adjust positioning using offset values.
  • Duplicate for bottom row (5 cutouts).
• Create one large cylinder cutout for exhaust:
  • Set to 32 sides for smooth curvature.
  • Position between ridges.
• Add four spherical indentations (heat vents):
  • Create a 16-sided sphere.
  • Duplicate in a grid pattern for symmetry.

4. Applying Boolean Operations

• Convert arrayed cutouts to editable poly.
• Use Boolean (Subtract mode):
  • Subtract cylinder, spheres, and rectangular cutouts.
  • Review mesh for errors.
• Fix potential issues:
  • Check for black shading errors (Z-fighting).
  • Use Cap tool to fix missing faces.
  • Manually adjust triangulation if needed.

5. Organizing Geometry Layers

• Save project before Boolean operations (Save As → version increment).
• Keep Boolean objects as backup:
  • Create a new layer (Booleans).
  • Move cutout objects to the hidden Boolean layer.

Creating the Exhaust Bracket

1. Modeling the Metal Frame

• Create a box for the bracket.
• Convert to editable poly and delete excess faces.
• Apply Shell Modifier for thickness.
• Ensure straightened corners for correct shape.

2. Positioning the Bracket

• Align with exhaust placement.
• Adjust height so it extends below support bars.

3. Adding Hex Bolts

• Reuse previously created hex bolts.
• Duplicate using snapping tool to place at bolt holes.
• Adjust size and position to match reference images.

Final Adjustments

• Verify alignment and proportions.
• Ensure shading is correct (fix any faceting).
• Check scan reference to confirm realistic placement.