After working on the gauge cluster, and various odds and ends, I saw winter approaching, and I battened down the hatches, and put away the welders, & tools till spring. I got started again in early march. I'm at the mercy of the weather, but it gave me all winter to research, plan, and make drawings....haha! I didn't do any of that crap! I'm disorganized as a crazy person. I tend to keep plans, and wiring diagrams in my head. My tools are flung everywhere. My shop looks like an apocalyptic nightmare of epic proportions.
I did get started in March though. It was time to build the exhaust system. I did have a plan for the exhaust. I wanted an X-pipe about where the transmission crossmember was at. I wanted 2 1/2 inch mandrel bent tubing. I have some exhaust expertise. I did exhaust fabrication for quite a few years. The mantra at that time was, "get it done, and get it out." I don't think exhaust systems are pretty. I don't like big chrome pipes sticking out the back end, like some version of redneck heaven. I would just as soon not know the exhaust system is even there.
I found the largest stainless muffler I could fit under the Jeep. It's made by Magnaflow. They have quality welded seam muffles. This particular muffler is their X series, dual in, dual out, and an X inside the chamber. About 24 inches long, and it must weigh 30 pounds. I still have the black pinky nail to prove it. I also got one of Magnaflow's very nice, stamped, and welded, stainless X-Pipes. Very compact piece, with 2 1/2 ID inlets and outlets. There's also a plan for stainless flex joints as far forward as will fit in the system, to allow for engine movement.
I used band style clamps at many of the joints, to allow for easy takedown of the exhaust, because I anticipate having to make some drivetrain changes, I. E. grenading the CryCorp differential at some point.
The front pipes were an interesting mix of stainless, and mild steel, because I couldn't find good quality header flanges in the proper shape, made from stainless. I needed at least 3/8 of and inch, because 1/4 inch flanges tend to bend under stress.
Here are some pics of the exhaust during fabrication, and after completion.
I welded an O2 sensor bung to each front pipe. I used mandrel bent tubing from various manufacturers. Aluminized tubing in 16 gauge is pretty good quality form all of the well known speed shops.
A little anti seize on the O2 threads.
The stainless flex joint added to the frt pipes. If You have headers, these things will keep them from cracking after they get some age on them.
The exhaust back to the muffler. Excuse the terrible pics. I was usually pretty tired by the time I took pics at the end of each day.