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I installed a 2.5" exhaust system today. Heres what all I used, links at the bottom. New downpipe without the dent, welded in a flex joint, to help with breaks in header. Also a Magnaflow highflow Cat, welded my existing bung in. Then a Delta 40 Flowmaster, and finally topping it off with a 2.5 Tailpipe.
I wish I did a turndown, not nearly loud in the cab at all. No drone, It still sounds like I'm driving a spinnaker down the road, but give me a weekend and another trip to oreilys and I'll get it done... or next week will turn into next month... Will turn into next year.
This was a fun weld job. I used .35 Stainless Steel flux from blue demon for differing metals. I welded through the paint, the galvanized coating, I even welded through a couple stickers. This stuff laid down a nice thick puddle for no leaks. My tip is go ahead and buy two pieces of whatever size couplings and make a practice welding run. Even if you know you got this, it pays alot to do a quick rip run. Next tip always slide your joints inside a coupling or have a overlap at each weld. Don't do a butt joint. Finally I didn't have any problems doing my last weld under the jeep. I laid every thing on the ground and welded it all together, saving my last weld for underneath the jeep. Picking a good spot in the middle, with it not in the mounts yet, and hanging kinda low. I welded one side, laid the gun down and crawled over and did the other side.
For my Downstream O2 bung after the cat I used a 1.5 hole saw to cut out my existing and drilled a matching hole in my new pipe using a step bit. I Laid the old bung over the new hole and welded a bead around it.
Ohh and most important This thing sounds AWESOME. It's alot more responsive too
TURNDOWN I replaced the Tailpipe with a turndown... I couldn't believe how loud it made it inside the cab. I thought my ears were bleeding, I also didn't like how it changed the sound slighly. SO i put the 2.5 tailpipe back on. I like the race car sound it makes, also I like how there is one more hanger at the end.
Well for awhile I've noticed that the rear end was starting to sag. The previous owner had just put some Pro Comp leaf springs on. Now that I think that they're fully settled, I got some Rough Country shackles & got those installed today. I can notice a big difference in the stance
Good looking build! That paint is sweet! Was the disc brake conversion a total bolt on or did you have to modify it?
Its not bad at all. The times it was a pain in the but was... The back plate hole is a tad too small to slip around the axle so you have to grind it a tad. And getting pads calipers and rotors for a different Cherokee.
Good looking build! That paint is sweet! Was the disc brake conversion a total bolt on or did you have to modify it?
Thank you.
Its not bad at all. The times it was a pain in the but was... The back plate hole is a tad too small to slip around the axle so you have to grind it a tad. And getting pads calipers and rotors for a different Cherokee.
Catback
This stuff laid down a nice thick puddle for no leaks. My tip is go ahead and buy two pieces of whatever size couplings and make a practice welding run. Even if you know you got this, it pays alot to do a quick rip run. Next tip always slide your joints inside a coupling or have a overlap at each weld. Don't do a butt joint. Finally I didn't have any problems doing my last weld under the jeep. I laid every thing on the ground and welded it all together, saving my last weld for underneath the jeep. Picking a good spot in the middle, with it not in the mounts yet, and hanging kinda low. I welded one side, laid the gun down and crawled over and did the other side. 
