Tips on Making Own Exhaust?

[Tito]

Alright, I need to redo the exhaust for the Bronco and want to stay on the cheap and do it myself as well (those dont always coincide). I am going to run stock manifolds and put the exhaust out the frame rail on both sides between the frame rail and my cage long arms and then mufflers under the floorpans and exit in front of the rear tires. I run just a rear 23 gallon tank and between my framerails is pretty full with the zf and doubler. I dont mind loud or really even hot on the floors it is open air in the summer anyways.

Interested in some tips for putting it together myself, things that helped, things you would do different next time.

 

[Hoppy]

im running parts house turbo mufflers like 30 ea
had the tubes bent here locally and welded on
you can allways use cheap flex tube and calmps

 

[Tito]

I have a set of mufflers and tips to use, just gotta make the rest. Figured I'd get some parts and pieces and put the puzzle together ;D

 

[bronco60-niner]

I just finished my new exhaust tonight. I'll have to renew my contributor status and post some pictures but I bought mandrel bends from a local exhaust shop (www.hoganperformance.com) very reasonable and great guys to work with. I bought a few too many 45's and 3' too much tubing but all in all I spend around $120 for everything in 2.5. I went up over the frame just past the body mount thats under the front floor pan with a 45 bend and connected another 45 to shoot the exhaust straight back into the muffler. All in all I used 2 90's, 4 45's and 3' of straight tube.

Im running a NP435/klune/np205 combo and with the front 4 link it was pretty tight but nothing hits. I was able to make my pipes all 1 solid piece all the way out past the frame and still get them out.

The mufflers are 1 chamber flowmasters and fit perfect under the floor and dump right past the rear wheel well. Its loud but not obnoxious loud like I was expecting.

Its a cut and fit process that takes it a little time but cheaper than everything I was quoted.

 

[Tito]

If you have any pics, shoot them my way I can post em up too
admin@nwbroncos.com

My issue is I am only running 1" BL so I have to cross over before the body mount.

 

[bronco60-niner]

sounds good. I'll get some for you tomorrow when I get home from work. Yeah I'm running a 2" body and cleared with about an 1/8 to 1/4 to spare

 

[scsm76]

Just buy a few mandrel bends in the size yo need from Summit, Jegs, or your preferred seller and cut and piece the system together. It took me a couple hours to make my 2 into 1 exhaust I only ended up using one J bend, one u bend, and about 15" of straight tube. When you use mandrel bends you can cut them any where in the bend and butt weld to a straight piece of pipe. After doing mine my only regret is that I didn't spend a few extra dollars to run stainless steel tube. Here is a couple pics of mine. Obviously not outside the frame rails but the process is about the same.

 

[TJK74]

I agree buy some mandrel bends from summit as well as any straight tubing.
Since you have the mufflers and tips already I dont see it costing you much. I'd say $75-$100 max

 

[FSRBIKER]

TK that looks real nice, where does it dump out? I like the flex pipes, are those stainless? Ever thought of selling that as an exhaust kit?

I just saw the 2 into 1 Gravy made for his Bronco, looked real nice. Maybe he can post some pics as well.

For those who are welding there own pipes are you using .023 wire and a Mig?

I agree buy some mandrel bends from summit as well as any straight tubing.
Since you have the mufflers and tips already I dont see it costing you much. I'd say $75-$100 max

 

[TJK74]

Yes they are Stainless steel flex couplers that I also got from summit. Below is a picture of the first set up without the flex couplers I did when I was running the old style Duffs long tube headers which I replaced with the BC headers when I got my Cage arms.
My exaust exits out the rear with a turn down.
Nope I have never thought of selling it as a kit since there are too many variables between engines, headers, transmissions, crossmembers and such
I welded mine up with .035 wire

 

[trailpsycho]

Probably saw this already, but here was my go at it. http://classicbroncos.com/forums/showthread.php?p=1089154&posted=1#post1089154