My exhaust has been on the way out for a long time. I was tempted to buy a pre-made solution, but all the local places wanted quite a bit of money, and I was not too excited about the pacesetter kits.
I ended up going the cheap route and just made my own.
Parts required:
Locally purchased:
Two 2 1/4 inch 90 degree elbows ROL 548704 $4 each
Two 2 1/4 inch 45 degree elbows ROL 548754 $4 each
2 inch ID to 2 1/4 inch OD adapter ROL 548523 $4
One 2 inch exhaust pipe clamp $1 each
Twelve 2 1/4 inch exhaust pipe clamps $1.50 each
Some straight 2 1/4 inch exhaust pipe $10
New exhaust crush washers $5
Total - About $50
Ordered from Summit:
Two 24 inch glass packs SUM-630812 $21 each
One Oval muffler with offset SUM-630122 $18
Flex Pipe SUM-642214 $30
$10 shipping
Total - $100
Stuff I had on hand:
Exhaust pipe expander. Purchase from harbor freight for $9 if needed. Item 37353.
Some scrap angle iron
Note: I did paint some of the pieces with black BBQ paint, but from my experience the pipe gets way too hot for the paint to stay on. I wouldn’t bother to do it if I did the project again.
First, remove your old exhaust:
As you can see, my catalytic converter was already gone, along with my flex pipe. They were both left along the side of the road somewhere….
In this picture I already cut off where it connected to the flex pipe.
Look down the end of the pipe. It should look like this:
Stick your exhaust pipe expander in it, and expand it out to this
If you cannot insert your exhaust pipe expander all the way, take another short bit of pipe to cover the end of the expander that is sticking out. If both ends of the expander are not in a pipe, the expander will break.
Next, start bolting things together:
Here I have the adapter to 2 1/4 inch pipe bolted up to the stock pipe, and the new flex pipe. Note: Keep the clamps facing down, not up like in this picture. Do not tighten any clamps fully until everything is in position!
Make sure to reuse all the old exhaust pipe mounting points and rubber hangers so you do not run into vibration problems. Here I reused the old bracket, but I had to extend it a bit.
Closeup of the mount:
Getting around the suspension:
The Muffler:
Here I used some angle iron to make the mount. Make sure to use locking nuts so you do not crush the rubber hangers.
This new routing of the exhaust pipe does hang a little lower, but it actually keeps the muffler much higher. I no longer scrape my muffler on steep driveways like I used to (which was probably what killed the old muffler), and the pipe under the tire is still protected by the tire itself.
This was a very cheap and easy solution to replacing my exhaust, and it sounds good. It is quiet with a nice low tone, but not like a fart cannon.
I will try to get an mp3 of how it sounds posted, but it might take a little while. I need to find my microphone.
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Originally Posted by MessyHonda
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