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      07-27-2009, 06:19 PM   #16
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Drives: E92 M3
Join Date: Sep 2006
Location: San Diego, CA USA

Posts: 10,201
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I would bet the tubing is hydroformed, this process uses very high fluid pressure along with a "mold" for the outside shape desired. The tubing is very purposefully shaped into a non round cross section in certain sections. My guess (without looking under my car recently) is that it is for clearance - either to other parts of the chassis or to the ground.

On another note we debated the need for exhaust shields quite a bit on this thread. My conclusion was just what IND is saying above. A user installed heat sheild sounds like a darn good way to play it plenty safe with any aftermarket exhaust system. Link to that thread here.