Just finished up my full 2.5" exhaust from the manifold back tonight. Turned out pretty nice I think. As far as the fabrication goes the front pipe was pretty much the only part that I had to fab. So here it is.

Here is the new front pipe along side the old crushed/crimped POS.



I ended up ordering a magnaflow muffler and tailpipe from that outfit that mudfrog works with. Fits great!








I apologize for the bad pics. I had to use my phone.

 

hey looks great! nice job! nice rear bumper too! lol

 

Here's a video I took with my phone. Hope you enjoy!
http://m.youtube.com/#/watch?v=gPXTW6XIPF0

 

hmmm link doesnt work.

 

yeah i want to hear that puppy. get a working link!
What is stock exhaust pipe size?
I need to search around near me to find someone who can mandrel bend pipe.

 

http://m.youtube.com/?rdm=4o0pyi5k0&...?v=gPXTW6XIPF0

I don't understand why this won't work

try this one.

 

2.25"

 

Sounds pretty good.

 

nice.

 

Ya 2 1/4" crush bent..so the ripples you see is just obstructing flow and causing turbulence.
And the dented front pipe necks down to about 1 3/4"...not good for flow!
If you do make a custom one follow the Op and add a peice of flex pipe! It'll help the header not to crack since it allows it to flex a little!

 

the camera is right next to the exhaust so I'm assuming it is a bit loud for that reason. However, is it really loud compared to factory? I'm more of a "keep it quiet" person. Although free flowing (and higher MPG) is the goal, so I'll live up some noise for that.

 

Well my exhaust currently is 2.5" mandrel bent down pipe, high flow cat & magnaflow muffler and a turn down..
Its loud when I get on it but thats because it has a turn down lol..If I had a tail pipe it'd be 10x quieter and I'm starting to think about putting a tailpipe on it actually.
Honestly loudness is going to be dependent on the muffler size. I run a 18" long pencil muffler..its called a Magnaflow XJ and is round vs the normal oval..Choose this style for clearence honestly!

If you want to keep it quiet & still get performance & MPG out of it, follow this...
2.5" mandrel bent downpipe, 2.5 highflow cat, 20-24" magnaflow muffler. Or similar to stock size..If keeping it quiet was a priority I would get a muffler with a 2.5" in & 2 1/4" out..that way your tailpipe can be 2 1/4"...this won't hender gains at all..and if there was a gain to be had from a 2 1/2" tail pipe, it'd be way too small to even feel it. So the 2 1/4" would be quieter and would be better!

For the cat I got a walker evans cat from autozone..Its at least 2x the size of the stock unit and I love it!
I'll be honest and stay I've done alot more to my jeep so my gains could be more/less...but anyway when I did the exhaust the only thing I did was the complete exhaust, and I feel there was a gain but the majority of it was at 3k+. Jeep feels more responsive on take offs and feels like it picks up & go quicker now as well. Its worth it in my eyes, I saw a steady 2mpg after this was done as well....your results may vary.

 

^Appreciate the post.

Well...I've got to do a whole motor too...so I might see if I can get a LOT of gain (MPG wise) there too. I don't really care about power (although 190 isn't a ton for a Jeep that'll be weighted with camera gear and a some accessories). I don't mind some sound, and would likely stick with 2.5 (simplier too I suspect).

 

Deffinetly easier..
If your doing your whole motor, clean up the head slightly. Any casting flaws can be cleaned up, port match/gasket matched. Deck the block a little..stock is like .0216..You can take it down to .01 without any issue..it'll bump your compression slightly, thus give you slightly more horsepower, it'll be more efficient since the quench is lower. Which will give you more mpg.
I intend to do the same to 0 deck my block..down to a .008 actually. Plane the head to make sure its nice and flat, and run a comp 200 cam. The comp200 can be ran with stock valve train. I will have no issue running this on 87 octane still and to boot it'll make about 80 horsepower more than stock. Pending I plan to run a header & get it tuned and such but another 80horsepower at the crank won't be to bad for the little amount of work it is.

 

Where did you find the 2.5 downpipe? My entire exhaust minus the downpipe is 2.5 and i cant find one anywhere. Thanks