A few weeks ago
I installed a FlowMaster Super 40 muffler on
the Bronco. The original exhaust was rotted
behind the muffler and it let the exhaust
fumes in the passenger compartment if you
had the back window down. The original
muffler had 1 2/1/4" inlet and two 2"
outlets. To simplify things I bought a
muffler with one 2 1/4" outlet. I used a 90
degree bend and a 24" down tube. Simple and
it fixed the fume problem.
4 1/2" Grinder with cutoff wheels
Stuff to have on hand:
Carb or Brake Cleaner
Hi Heat Paint
That is until
the first time I took it off-road. I was
crossing a 3' x 3' washout and caught it on
a rock. See the aftermath below.
I have seen a
few other Bronco Owners go up and over the
frame the out so I decided to go that route.
After removing the rear tire I cut a 6" wide
square out of the bed support.
I also cut a 3"
x 3" square out of the sheet of steel below
Here is a view
of both cutouts.
Next I used two
2 1/4" I.D. 90 degree bends and a a 2 1/4"
I.D. to 2 1/2" I.D. adapter to get the
exhaust up and out above the frame. The
pre-made bends were about 6" too long to fit
in the right place. after tacking, checking
then re-cutting and trying about three times
I finally got it where I wanted it. A
grinder with a few cut-off wheels makes it
I used some
magnets and a car jack on the muffler to get
it all aligned then tack welded everything
in place. I then removed the muffler on back
and welded it all up. I had a 1/4" gap where
the two 90 degree bends met that I had to
fill so it wouldn't leak.
All welded up
and ready to install. I shot a quick coat of
heat resistant paint on the areas I couldn't
reach once it is installed.
Once welded in
it sits nicely centered in the hole.
The fat muffler
just fits in it's place. I still have to
make a new mount for the hanger. The welds
may be ugly but they should hold.
Up and out.
Next weekend I
will figure out exactly where I want the
exhaust to exit the vehicle. I am thinking
of having it exit out the quarter panel in
front of the rear tire.