304 Stainless Exhaust in new Build (with pictures)

[dirwin]

Just started getting going on the chassis of my 72. The frame was absolute crap so I went with a new JBG frame. With this one I decided to go with a 3.5" James Duff suspension, 2" body lift, 351/ZF/Atlas driveline and went with BC Bronco's headers.

I've not really cared for the pre-bent exhaust that's out there, it's good and functional and all, I just don't care for the plain look and heaven knows I love to over complicate stuff for myself. So I decided to teach myself how to tig weld stainless and do a 2.5" mandrel bent, weld up exhaust myself. I'm an absolute amateur with the tig but I did decide to do a merge pipe and exhaust on my Mustang prior to taking on the Bronco. I've got to give props to another website here though, Jody at www.weldingtipsandtricks.com is absolutely a fantastic resource, his videos that he post for free are a great tool.

So, I ordered a bunch of 2.5" 16 gauge 304 stainless bends, 15, 30, 90 and 180 degree bends, one 2 in, 2 out Magnaflow muffler with the internal crossover and a new bimetal blade for the bandsaw and away I went. My goal was a single muffler dual setup that brought 2 pipes out the passenger side. Here is the photo trail of the work. All I lack is one hanger on the rear pipe section that I should be able to do tonight after work.

One observation I will make, I am very impressed with Chuck's headers, of all the headers I've used so far with the Broncos, these are by far the best.

 

[gnsteam]

That looks fantastic! Great Job.

 

[WheelHorse]

OK, now pull it all off and polish it to a chrome like finish LOL.

Looks really awesome.

 

[john monroe]

WOW,real nice.........I live in Michigan whenever you're ready

 

[stus70brc]

Looks good! That's how I did mine up front going into my Magnoflow 2 into 1 muffler How do you like that new frame??

 

[dirwin]

Michigan is a LONG way from Texas and there is no polishing in my future, LOL!

I love the frame, it is a very quality part. I had them build it without the front and rear shock mounts or the radius arm mounts so that I wouldn't have to cut anything off and made installing the JD stuff easier. I did have to trim the coil spring mounts to clear the dual front shocks but it would have worked perfect for the stock set up or putting a shock on each side of the coil spring. The whole deal is just stouter than stock and the coil mounts are bigger than stock. I was especially impressed with the welding. I know it's done by hand but it seriously looks automated. I had to sharpen up my Mig welding to try and match the welds they had done when I did the shock mounts, tank brackets, battery box and steering reinforcement. Purist might call it a Frankinbronco since the frame had to be replaced, but it is sure nicer than patching up the old one that had been chopped to hell and back by the previous owner.

I thought about doing the 2 into 1 set up and changed my mind. I have a Raptor and I really like the way the exhaust is done on that one so I kind of tried to duplicate it. I think it was worth it and all in all, I have about 14 hours and $400 in it so I think it was worth it just for the custom aspect alone.

 

[BluebroncoNC]

Purdy!!!!

 

[68rustbucket]

Very nice job!
Where did you get the starter pipe that leave the header? When I had my first exhaust system built for my BC header, the exhaust guy had a hard time flaring a pipe big enough to fit the flange. Finishing up Atlas 4 install, will be having exhaust system #2 built. Wanna do mine in San Marcos?

 

[savage]

Nice job, I like the way you did the dual pipes, and how you exited them out the side.

 

[dirwin]

I got all of the stuff from Columbia River Mandrel Bending.

Here is the link to the transition cones. They have just about everything you can imagine for exhaust or turbo plumbing. They also have the standard 3 hole flange that is used for the BC Bronco headers.

http://www.mandrel-bends.com/catalog/transitions-forms-45/transition-cones-211/

The flange is here.

http://www.mandrel-bends.com/catalog/2-50-3-bolt-universal-exhaust-flange-1-4-mild-steel-4241.html

Of all the places I've found, they are the most reasonable prices for stainless steel for sure. Hot rod shops will charge you out the nose and I'm pretty sure Columbia River is where they buy all the stuff they sell anyway. Mandrel machines start over 100K so there aren't many companies who have one.

Thanks, I really like the 2 out, it's unique and I haven't seen one done that way yet (not that there isn't one, I just haven't seen it).

 

[dirwin]

Rear hanger is done, exhaust is now complete! Going to try and put the body on it tomorrow if I get time.

This it the section of the coil mount that I had to trim on the frame.

My best attempt at matching the welds when I welded the rear shock mounts. A little better with a MIG than the TIG...

 

[68rustbucket]

Dirwin,
What size is the transition cone that fits the BC headers?

 

[DirtDonk]

Extremely sanitary transitions there at the back, where most systems fall on their face. It's an awkward spot at best, but looks like you nailed it.
Do you know how far below the body the tubes will sit at the exit? If not, I guess you'll see tomorrow!
Definitely keep the pics coming. Looking forward to seeing more of this build.

And just what is that little pump-thingy under the alternator? Looks interesting. Got more pics of the engine area?

Thanks

Paul

 

[Yeller]

Nice work! Glad to see I'm not the only one that builds his own exhaust

 

[ILikeBond]

Wow, very clean chassis overall and great job on the exhaust. Also can't wait to see how it looks with the body. Kudos.

 

[Unknown]

Exhaust envy! Nice work!

 

[Yeller]

Impressive. Perhaps some of the finest work posted here. Faced with a similar project, and likely as much a perfectionist, curious how you make square cuts on the bends? Mine always seem to be off angle such that I end up with a gap.

I cut them with a band saw unless it will fit in my cold cut chop saw. Sometimes the metal will shrink or the bans saw with move out of square and cause a gap or i miss the angle just a bit. When that happens I dress the cut on a belt sander to square it up or adjust the angle some.

For doing this type of work a belt sander is priceless. I use it to clean fine tune and debur parts and to sharpen my tungston for the tig.

I know everyone cry's about fouling your tungston with contamination from the belt, which is true you do to a very, very minimal amount. I can promise not enough that you will ever know, you'll get more contamination from the dust in the air and surface of the material than from the tungston.

 

[dirwin]

Under the alternator isn't a pump, it's how the Vintage Air Frontrunner exits the A/C lines.

This is the second Frontrunner setup I've used on an EB and I love it. No issues with radiator clearances using an electric fan and shroud.

The install of the body didn't go well at all. Finally got the opening for the ZF shifter right and was able to get the body bolts from the forward floorboard to the tailgat tight, the damn front clip was replaced and it lacks 3/4 inch to sitting down on the body mount, it's a damn mess. Looks like I'm going to have to cut the whole damn front clip off to get it lined up.

As for the exhaust, even after a ton of measuring on my 74, it's exiting 7 inches below the damn body, I knew it was going tobe a little lower but 7 inches looks like crap. SO, off will come the tail section of the exhaust and I'll have to cut it up, move the exit back and up a little, my goal is 2 inches below the bottom of the body. I'll post some pics, I just got pissed and walked away from it last night and didn't take any.

 

[Yeller]

Be sure to check fender and door alignment before getting to cutting on the front clip. Make sure the fenders and doors line up first. It looks like your frame is powder coated, I've had frames move during that process and create all kinds of issues. You may have to get creative shimming the body mounts if the body parts all line up, I've had all sorts of issues with the doors not lining up even though everything did prior to paint and coating.

 

[dirwin]

That's the plan. I've got to fit the doors and fenders to make sure where I'm at first. I had to do some creative shimming on my 67 to get the doors to fit right as well. We'll see...