Custom exhaust tubing and non-circular tube for automotive and motorsport applications
Clients and projects using our shaped tube
Strong and space-saving: stainless steel and aluminium tubing solutions for automotive and motorsport
Timeless Tube is a UK specialist manufacturer of custom-shaped tubing for automotive, motorsport and performance engineering applications.
We cold-form round tube into oval, flat-sided oval, radiused square and other non-circular profiles, providing automotive engineers and fabricators with alternatives to conventional round exhaust and structural tubing or tube components.
Our shaped tube is particularly useful where ground clearance, packaging space, strength or component geometry makes standard round tube unsuitable.
Applications include performance exhaust systems, custom exhaust fabrication, manifolds, chassis components, structural supports, vehicle interiors, motorcycle components and specialist automotive assemblies.
From a single development length to repeat production quantities, we work with automotive manufacturers, motorsport engineers, exhaust fabricators and specialist vehicle builders to develop tubing around the requirements of the finished component.
Custom tube forming for prototype and production automotive parts
Automotive projects often don't fit off-the-shelf catalogue sizes. Our flexible cold-forming process allows us to develop new tube sections without the need for a dedicated die for every profile. This makes Timeless Tube particularly suited to prototype and product-development work, as well as repeat manufacturing once the design has been proven.
Our engineers can work from your required finished dimensions, packaging envelope or drawings to determine what material is needed and whether existing tooling can be adapted for your required form.
Production can range from a single 5.7m length to thousands of lengths, with a quick turnaround depending upon availability of the round tube we cold-form.
Contact us if you need a specific part for a proof of concept or for volume work quotations, or you want to learn more about the tolerances we can achieve.
Flat-sided oval stainless steel tubing used for a custom engine manifold
Exhaust tips for Jaguar (flat-sided oval tube, stainless steel 304, 167 x 66 x 3mm)
Cold-formed complex tube components made from high-quality materials
We form most automotive tubing from 304L and 316L stainless steel, because it can withstand extreme temperatures and is highly durable, which makes it well-suited as a safe, reliable material for exhaust systems.
We also fabricate automotive components from aluminium, titanium and copper-based alloys. These metals are also corrosion-resistant, highly durable and low maintenance. They also offer an excellent strength-to-weight ratio, which can help to reduce the weight of the vehicle and improve fuel efficiency.
Non-circular exhaust tubing for restricted spaces
Flat-sided oval exhaust tubes
For applications requiring a flat section, flat-sided oval (FSO) tubing combines two flat faces with radiused sides.
This profile is particularly useful for performance exhaust systems where ground clearance or component clearance is critical. A conventional round exhaust requires the full outside diameter of the tube in vertical space; by using a wider, shallower flat-sided oval profile, exhaust fabricators can package a useful tube section into areas where a larger round tube may be difficult to accommodate.
This can be particularly useful for lowered and performance vehicles, motorsport applications and exhaust routing around chassis, suspension or drivetrain components. Timeless Tube manufactures a wide range of flat-sided oval exhaust tube sizes, including large profiles for applications where underbody space is restricted.
- Reduced section height: helps improve ground clearance and package exhaust tubing within restricted underbody spaces
- Adjustable forming tools for tight tolerances on critical parts
- Flat mounting surfaces: attaches securely and easily to other brackets, plates or components
- High section strength: independent deflection testing found our 30 × 15mm stainless steel FSO section to be 54% stronger than its equivalent starting round tube under the tested minor-axis loading conditions
- Custom development potential – useful for prototype, specialist vehicle and low-volume production applications
Compared with circular tube, a flat oval profile can allow an exhaust section to pass through restricted areas beneath a vehicle or around other components.
| Round tube OD | Flat-sided oval tube dimensions | Wall thickness |
|---|---|---|
| 1 ¼″ | 37 × 22 mm | 1.5 mm, 2 mm |
| 39 × 19 mm | 1.5 mm, 2 mm | |
| 41 × 15.5 mm | 1.5 mm, 2 mm | |
| 1 ½″ | 48 × 21 mm | 1.2 mm, 1.5 mm, 2 mm |
| 43 × 28 mm | 1.5 mm, 2 mm | |
| 45 × 25 mm | 1.5 mm, 2 mm, 3 mm | |
| 2″ | 62 × 31 mm | 1.5 mm, 2 mm, 3 mm |
| 2.5″ | 78 × 39 mm | 1.5 mm, 2 mm, 3 mm |
| 86.5 × 27 mm | 1.5 mm, 2 mm, 3 mm | |
| 3″ | 91 × 51 mm | 2 mm, 3 mm |
| 99 × 38 mm | 2 mm, 3 mm | |
| 3.14″(80 mm) | 95 × 55 mm | 1.5 mm, 2 mm |
| 3.5″ | Please enquire about sizes that can be formed from this tube. | |
| 4″ | 128 × 55 mm | 2 mm, 3 mm |
| 4.25″ | 133 × 63 mm | 2 mm, 3 mm |
| 4.5″ | 138 × 73 mm | 2 mm, 3 mm |
| 5″ | 167 × 66 mm | 2 mm, 3 mm |
| 6.14″ | 195 × 85 mm | 3 mm |
Oval exhaust tubes
Our oval exhaust tubing offers a simple way of reducing the vertical height of an exhaust section without moving directly to a completely bespoke fabricated component. Where only part of the exhaust requires additional clearance, selected profiles can also be transitioned back towards round tube at t for connection to conventional round exhaust tubing and components.
- An elliptical profile ideal for components exposed to airflow such as exhausts, roll cages, and chassis parts
- Over 300 existing sizes — made from 1/4 inch to 8 inch diameter round tube
- Streamlined shape reduces air drag compared to round or square tubing
- Connectors and bend tooling available
- Twisted oval tube option available for decorative trims and heat transfer applications
- Forming tools can be adjusted, allowing for tight tolerances on critical parts
Mirror polished stainless steel tube exhaust pipe made by cold-forming circular tube in grades 304 or 316L
| Round tube OD | Oval tube dimensions | Wall thickness |
|---|---|---|
| 1 ¼″ | 39.5 × 21 mm | 1.5 mm |
| 35 × 27 mm | 1.5 mm | |
| 1 ½″ | 47 × 25 mm | 1.5 mm, 2 mm, 3 mm |
| 43 × 30 mm | 1.5 mm, 2 mm, 3 mm | |
| 2″ | 61 × 37 mm | 1.5 mm, 2 mm, 3 mm |
| 65 × 33 mm | 1.5 mm, 2 mm, 3 mm | |
| 2.5″ | 76 × 50 mm | 1.5 mm, 2 mm, 3 mm |
| 3″ | 92 × 56 mm | 2 mm, 3 mm |
| 98 × 50 mm | 2 mm, 3 mm | |
| 4″ | 121 × 76 mm | 2 mm, 3 mm |
| 128 × 70 mm | 2 mm, 3 mm | |
| 143 × 45 mm | 2 mm, 3 mm | |
| 139 × 53 mm | 2 mm, 3 mm | |
| 5.07″/ 5.32″ | 151 × 101 mm | 2 mm, 3 mm |
| 167 × 87 mm | 2 mm, 3 mm | |
| 6″ | 200 × 100 mm | 2 mm, 3 mm |
Radiused square tube for automotive structures
Radiused square tube combines relatively flat faces with rounded corners and can provide efficient use of available packaging space.
Potential automotive applications include structural supports, chassis components, frames and specialist vehicle assemblies.
- Blended corners and subtly convexed sides provide greater structural strength than circular tube in certain load conditions
- A contoured alternative to angular box section, with rounded corners that are less prone to cracking or fatigue than sharp-edged square tubing
- Offers better use of space than round tube
- Twisted square tube and radiused rectangle tube options available
- The flat faces can also provide useful mounting and fabrication surfaces
| Round tube OD | Radiused square tube dimensions | Wall thickness |
|---|---|---|
| 1″ | 23 × 23 mm | 1.5 mm |
| 1.25″ | 28 × 28 mm | 1.5 mm, 2 mm |
| 1.5″ | 34.5 × 34.5 mm | 1.5 mm, 2 mm |
| 2″ | 45.5 × 45.5 mm | 1.5 mm, 2 mm |
| 3″ | 66 × 66 mm | 1.5 mm, 2 mm, 3 mm |
| 4″ | 88 × 88 mm | 1.5 mm, 2 mm, 3 mm |
Exhaust silencer for motorbike (end-formed perforated round tube, stainless steel 409)
Brake-cooling kit for Renault Mégane 3RS sports (flat-sided oval tube, aluminium 6082 T6, 87 x 38 x 1.6mm)
Welded starform exhaust baffle (end-formed laser-cut round tube, stainless steel 409)
Motorbike handlebars (twisted square tube, stainless steel 316L, 28 x 28 x 1.5mm)
Tube end forming: reduction, expansion, swaging and pressing
As well as forming the main tube profile, we offer specialist tube-end forming and tube manipulation for automotive components. These components are made to fit adjoining parts without the need for unnecessary additional fabricated joints.
Tube reduction and expansion
Using highly flexible tube manipulation machinery, our engineers can adjust round tube diameters by up to 20% of the original size.
- Precise diameter adjustment (within the specified range of each tool) allows for minor adjustments to be made until an optimal fit is achieved
- Cost-effective for both custom parts and high-volume production
- Bent tubes can be formed close to or directly on a bend — without the need for additional tooling
- Coning, flaring and swaging services are also available, for both circular and non-circular tube profiles
Pressed tube ends
We can press the ends then drill them for screws, reducing the need for additional brackets.
Tube reduction for round tube
Tube expansion for round tube
Oval to round tube exhaust transitions
Tube-end forming tools enable our fabricators to return shaped profiles such as oval and square tube back to round tube at the ends.
This allows the central section of the exhaust to use a flatter profile where clearance is restricted, while the ends remain compatible with conventional round exhaust tubing, clamps or adjoining components.
The result can be a more integrated component with fewer separate transition pieces.
Tubing for chassis, racks and vehicle structures
Non-circular tubing is not limited to exhaust systems.
Oval, flat-sided oval and radiused square profiles can also be used for vehicle frames, chassis supports, luggage racks and structural assemblies where the geometry of the tube provides packaging, strength or aesthetic advantages.
Our flat oval tube is regularly specified for applications in demanding transport environments such as railway and aerospace: safety-critical sectors that demand the highest-quality tube components.
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Stainless steel luggage racks made from our flat oval tube, used onboard commuter trains in Europe and high-speed passenger trains in Japan
Automotive and motorsport tube applications
Our tube-forming capabilities can be applied to components including:
- Performance and custom exhaust systems
- Exhaust transitions and extensions
- Suspension wishbones
- Inlet manifolds
- Seat adjustment tubes
- Headrest armatures
- Seat frame components
- Support arms for car boots
- Cross tubes
- Support tubes for chassis
- Luggage racks
- Shift levers
- Radiators
- Bumper edging
- Internal structural frameworks
- Roof rails
- Cant rails, skirts and trims
- Transmission linkage tubes
- Instrument panel tubes
- Motorcycle swing arms
Automotive and motorsport tubing FAQs
Talk to a tube engineer today
Speak to our team to get started. Request samples, drawings, or technical datasheets.
