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Exhaust(ing) Work

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Exhaust(ing) Work

Post  Ryan McKee on 2/22/2012, 12:51 pm

So for the past few weeks I've been working on replacing my entire exhaust from the header back. It's taken a LOT of work and has been extraordinarily annoying, as far as I'm concerned, but I am almost done, pending the arrival of the 2 new O2 sensors from RockAuto.com.

I first cut out the old muffler on the trails a few months ago during a club run, and then ran only a cat/front pipe for 3 months. Unfortunately the front pipe rusted through and there was a massive exhaust leak out the header (bye bye, MPG) so I finally replaced it. Problem was that the bolts were rusted and seized, so I had to cut off the output of the header flanges and fab up a new flange mount for the front pipe.

Then went in the Magnaflow front pipe & catalytic converter system, followed by modding a Banks Monster 2.5 muffler/tail pipe. That wasn't much fun either, as I had to weld together a bracket to get the muffler to couple to the catalytic converter output.


Old Cat/Front Pipe, and header flange that needed to be cut off













New Magnaflow kit









Then came routing the new Banks system







And welding a new coupler








Now I just need those NTK sensors and I'll have a real exhaust again!

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looking good

Post  Mark on 2/23/2012, 11:57 am

Hey RYAN. It looks like you have things under control over there.
Almost done ,good job.




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Re: Exhaust(ing) Work

Post  Ryan McKee on 2/24/2012, 12:50 pm

Thanks Mark! Almost there... now I'm just waiting for the downstream sensor to arrive.

Upstream came today!


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Built '99 TJ on 35s - My JeepForum Build Thread


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Re: Exhaust(ing) Work

Post  Ryan McKee on 2/29/2012, 9:01 am

Video of it finished.




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exhausting work

Post  Mark on 2/29/2012, 9:55 am

Hey RYAN, The exhaust sounds great , i'll bet you are relieved to have it finished.
Now it is time to start on another mod. Will it ever end.
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Re: Exhaust(ing) Work

Post  Ryan McKee on 2/29/2012, 10:20 am

Markmmaark wrote:Hey RYAN, The exhaust sounds great , i'll bet you are relieved to have it finished.
Now it is time to start on another mod. Will it ever end.

Already busy planning for the next one....... Very Happy

Wheeling soon?

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Built '99 TJ on 35s - My JeepForum Build Thread


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Ryan McKee
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