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Exhaust Rebuild/Changes 200

posted by  PhoenixFire on  Tue Feb 7 20:16 CST 2012
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last visit: Sat May 10 16:55 CST 2014
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Seems that EVERY car I have ever had, I have had to completely replace the exhaust system, so why should I expect anything different this time? Time has come. It sounds a bit stock car-ish right now, and it is the manifold. This may seem like a no-brainer, but I have done dumber things before, and I just wanted to check my sanity with some of you first. I figure, while I have it apart to replace the manifold, I would make some changes. First, hollow out the catalytic converter. Yes I know the legal aspects to it, but I have done this on other vehicles before with no negative results and only positive changes. Is this NOT recommended, and if so, why? Next, remove the first muffler (just behind the cat). I have seen systems for sale with out it, or even kits to remove it, so why not do it my self? Pros/Cons on this? Next is where the real insanity happens, I have done this once before on a truck i had. I am a design-engineer and pipe fitter by trade, I know pipe and fittings. I was pondering making a whole new exhaust system from either 2" or 2 1/2" sch. 40 galvanized pipe. I have the means to make it all threaded (except for connections to manifold/cat/muffler). I am tired of replacing exhaust parts that rot away after just 2 years or so. I now live on the coast of Maine, not the most car-friendly environment. I want to not have to worry about the pipes again. Ever. Also, while I am doing this I will be re-routing the exhaust OVER the rear axle, for a possible lift in the future.
Thoughts on this? It worked really well on a large V8 dual exhaust truck I had, sounded great and (some how) even passed inspection. Welding (to manifold/cat/muffler) would be done by a friend of mine, everything else can be sourced from my shop, galvanized pipe, fittings, stainless steel hardware (for hangers).
Ok, back to sanity. I would like some opinions on where I should get my new manifold from. What is junk, what is good, who has the best prices? At the very least, the manifold NEEDS replacing VERY soon.
Thanks
--
-Kilted Chaos Manager-






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