Custom Exhaust Fabrication Shop
Design and fabricate custom exhaust systems and headers
Overview
Exhaust fabrication shops charge $800-$5,000 per custom system.
Completing 120-300 systems annually generates $200,000-$900,000 annually with 55-75% margins.
In 2025, performance enthusiasts want custom exhaust for sound, performance, and fitment.
Services include custom exhaust system fabrication, header design and building, turbo exhaust manifolds, catback exhaust systems, muffler and resonator work, and mandrel bending.
Successful exhaust shops master exhaust design for performance and sound, use mandrel benders for smooth bends, TIG weld stainless and mild steel, dyno test for performance gains, and build reputation through sound and performance.
Can specialize by vehicle type or performance level.
Marketing through performance shops, dyno days, car meets, and social media (exhaust sound videos popular).
Required Skills
- Exhaust Design
- TIG Welding
- Mandrel Bending
- Performance Tuning
- Sound Engineering
- Fabrication
Pros and Cons
Pros
- Strong demand from performance enthusiasts
- Custom work commands premium
- Repeat customers as they modify vehicles
- Can specialize in performance niche
- Exhaust sound videos great marketing
Cons
- Expensive mandrel bender ($10K-$40K)
- TIG welding skills required
- Time-intensive custom work
- Noise regulations in some areas
- Competition from bolt-on exhaust kits
How to Get Started
- Master TIG welding and exhaust fabrication
- Invest in mandrel bender and equipment
- Learn exhaust design for performance
- Set up shop with lifts and tools
- Market through performance community
- Document sound and performance gains
- Build reputation for quality custom work
Explore More Custom Fabrication & Modification Ideas
Discover additional business opportunities in this category.
View All Custom Fabrication & Modification Ideas →