Custom 2:1 Exhaust

[Torkman66]

Started building exhaust today. Started with Hooker headers and 2.5” pipe front to back. Magniflow muffler. Easy to do if you have a chop saw and decent mig welder. Lots of folks say you need a tig welder, not true at all. I’ve made many exhaust systems with my mig. Welding is easy, penetrates well, lays down flat, and easy to grind for a final finish. I buy mandrel bent steel kit $150 on Amazon, the y-pipe, muffler, and hangers. Takes two days and total cost around $300.

 

[Torkman66]

Also, in the first picture the weld in the center has not had a flap disc on it yet. There are actually 4 welds in the first picture and they are barely noticeable after grinding. Final thing will be to coat entire exhaust with either VHT exhaust silver or Eastwood. In pic 3 you see a clamp. I always use clamps on mufflers so they can easily be replaced and it also makes the entire exhaust easier to remove if needed. Everything else is welded. Planning on a 60° out behind tire and a few hangers.

 

[Torkman66]

Would also like opinions on a corner 60° outlet behind tire or a 90°. Thanks.

 

[Scoop]

Nice work. Love my 2 into 1 Magnaflow exhaust. You'll like it.

I have done 3 of these Super Single set ups using Magnaflos. My trail rig is straight back and turned down about 30 degrees. It's a bikini top only no tail gate semi buggy so no issues with fumes. On both my 78 and a 72 I just sold I had the exhaust exit at 45 degrees behind the rear tire. I've not had any issues with fumes on either. Here is a pic of the 72.

Personally I do not like the looks of a 90 degree exit.

 

[Torkman66]

Nice. I think I’ll go with the 45° like yours.

 

[bronco italiano]

Did you get everything of amazon?

 

[stupidboy]

Mine is 90

 

[Torkman66]

I got the y pipe from Amazon:
https://www.amazon.com/dp/B07FDX8YKY/?tag=classicbroncos-20
And the pipe kit from Amazon
https://www.amazon.com/dp/B088CYH6HX/?tag=classicbroncos-20
They sale the same pipe kit with half the amount of pipe. You can use that smaller kit for a single and require the larger kit for dual. Plenty of pipe with a lot left over.
Bought the muffler, hangers, and two clamps from Summit.

 

[Torkman66]

When welding with mig, practice on a few pieces first in order to find the right heat and wire speed settings. I have always found that a very high heat (I max out my Lincoln 140) and a med wire speed makes for good penetration and flat smooth welds on exhaust pipe. With the high heat you must stitch weld to avoid burn through.

 

[BGBronco]

I went the dual route becuase the voices around me recommended it. Knowing what I know now, I would have done 2-1. Nice clean job on yours!

 

[Madgyver]

I fabricated mine...

 

[stupidboy]

I did mine

 

[Torkman66]

Finished out the back to a 45° behind tire. Two hangers. One just past muffler and one just before the 45° turn toward tire. Wrapped muffler with heat sheet to keep floor heat down. Only thing left is to disassemble and paint with high heat silver so it does not rust. Only ended up using one clamp in front of muffler. Welded tail pipe section to muffler for tighter fit. If I ever need to replace muffler I can cut it off and reweld new one on. Finally, put a slight downward tilt ( about 2°) on tail pipe so moisture runs out and does not sit in pipe. Last tip is when determining final location of tailpipe section, mock it up and then jack up rear at frame so tire hangs down to its lowest point. As long as you still have clearance, no problem with full leaf spring travel hitting pipe.

 

[chuck1022]

is this a catalytic converter?

 

[Torkman66]

No. Its a Flux Capacitor.

 

[Bitch'nBronco]

is this a catalytic converter?

 

[Shimmy]

@Torkman66 nicely done!! like how you did the exit too

 

[chuck1022]

I really like catalytic converters.....or I should say I really dislike the smell of cat-less exhaust. Anyways...mentally building exhaust.....and I thought a 2 into 1 cat would accomplish both of my needs......turns out they make them.

 

[stupidboy]

I really like catalytic converters.....or I should say I really dislike the smell of cat-less exhaust. Anyways...mentally building exhaust.....and I thought a 2 into 1 cat would accomplish both of my needs......turns out they make them.

I guess you could say you told him! Lol