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I am planning to build my own exhaust-system (X, maybe H). I am planning to use a diameter of 2.5", and as I am a designer in a company that only uses stainless steel I can have all the stainless parts extremely cheap. But now I am stuck with a problem: the diameter is 2.5" but the thickness is 1.5mm (0.059"). Normally the exhausts here are about 1mm (0.039"), should I use the thicker steel or not?
I don't know if there are more negative things besides the added weight and more difficult to bend...
 

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Sounds OK to me, other than the extra weight and being able to bend it like you said . . .

You might check around to make sure you can get acces to a mandrell bender that can handle your material --- I tried to get a couple local shops to bend some .120" mild steel tubing and they all were afraid they would damage their bender trying.
 
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