PLM Case Studies — Custom Fabrication & Manufacturing
From one-off prototypes to full production runs, Brockett Built takes your concept from idea to finished, production-ready parts. TIG welding in steel, stainless, aluminum, titanium, and Inconel; small-parts manufacturing; short and full production runs — all built in-house in the USA. Below are real projects we've engineered and built with our clients and partners.
Start Your Project — Request a Quote →
Trusted by motorsports, aftermarket & manufacturing teams
Full Custom Exhaust System — Lexus GX470
Headers · Y-Pipe · Catback · 304 Stainless · TIG-Welded
The Project: A complete ground-up exhaust system for the GX470's 4.7L 2UZ-FE V8 — headers, Y-pipe, and catback — designed to fit this platform exactly, not adapted from an off-the-shelf kit.
Our Build: Working from a full 3D-scanned CAD design, we fabricated the entire system in 304 stainless — mandrel-bent tubing, TIG-welded and back-purged for a clean, oxide-free inside, 3/8" flanges to resist warping, and precise merge collectors. Every joint hand-welded in our central Illinois shop.
The Result: A true bolt-on, OEM-fit system — now a flagship product line, with headers, Y-pipes, and catbacks shipping to GX470 and 4th-gen 4Runner owners nationwide.
Ground-Up Exhaust System — 1st Gen Ford Bronco Coyote Swap (Classic Ford Broncos)
Coyote Swap · Full Custom Exhaust · Production Partner · Private Label Manufacturing
Project photo coming soon
The Project: Classic Ford Broncos needed a complete exhaust system for a Gen-4 Coyote-swapped 1st-gen Bronco — an engine-and-chassis combination with almost no aftermarket support. The project came to us as the fabrication partner.
Our Build: From a modular header and crossover design, we fabricated the full system — long-tube headers merging into a custom dual X-pipe and catback run to the tailpipe — all TIG-welded 304 stainless, built to clear a swap that nothing off-the-shelf fits.
The Result: A production-ready exhaust system for CFB with recurring batch orders — a true private-label manufacturing relationship, engineered and built from scratch.
Production Shop Tooling — Tube Fixture & Flange Welding Fixture
Product Development · Precision Tooling · In-House Product Line
The Project: We needed better tooling for our own production welding — and saw that other fabricators needed the same. Two precision shop tools, taken from idea all the way to a shippable product.
Our Build: We brought both to production: the adjustable V-block Tube Fixture, which spins tube, bends, and pie cuts true on a welding positioner, and the billet Flange Welding Fixture, which holds and back-purges 2-bolt, 3-bolt, turbo, and V-band flanges. Both precision-machined and made in the USA.
The Result: Two live products now selling to fabricators nationwide — proof we can carry a concept all the way to a finished, production-run product.
Need a Fabrication & Manufacturing Partner?
Tell us what you're building — a prototype, a production run, or a full product line — and we'll take it from concept to finished parts.
Start Your Project — Request a Quote →
Or call the shop direct: (309) 256-6993