Novak Headers And Exhaust Pipe Sizing

Still looking for more pics.

 

I was so excited to knock this project out...... Got the dreaded backorder email.....

 

Parts are starting to roll in for this project.
Called and talked to Novak... Headers are still on backorder, they ordered another 20 sets to try to get priority with Sanderson.....
I have decided to run 2" pipe from the header collectors into a y.
At the intersection of the y, the pipe increase to 2.25" and run to the muffler.
The tailpipe will exit the muffler with 2.25" and run out the passenger side rear corner.
Piping will be stainless. I have stainless wire for my MIG welder..... but hopefully some quality beer will coerce my brother into TIG welding it up for me.
Muffler is a Walker quiet flow stainless for a Cadillac V8. This system should breathe well within general dauntless operating range while keeping noise to a minimum.

 

A few more parts trickling in. I may have over ordered just a bit, but with current shortages and lead times I want to have plenty of stock on hand.
I need to order a couple 2” bends and one other special piece.

 

When I did mine I also went around the front of the oil pan and over the front drive shaft. If you want it up out of the way I don't believe there is any other route. Used a Flowmaster muffler and really like the sound.

Bought all the pipe from Columbia River Mandrel Bending.

 

I just saved that page. Slick setup im going that way over the winter.

 

I have been studying your old exhaust thread quite a bit!
My latest plan is to mirror your system with the drivers side wrapping to the passenger, Y together, go over the cross member to a muffler and out the passenger side corner. My centered Diff and D20 makes a couple things easier and a couple things harder than a traditional setup.

 

Just got a shipping notification from Novak on the headers!

 

I scored these 3 mandrel bends on ebay way cheaper than summit. They appear to be "2nds" but I don't care.

 

A critical part showed up today! It was a bit spendy..... but I think it will be worth it.
SPD in Rancho Cordova, Ca built this exhaust merge for me. Dual 2" inlets and a single 2.25" outlet.
I talked with the owner a little bit about my plans and it turns out he is an early jeep guy too! Didn't earn me a discount though...

 

I noticed you have a heat shield on your muffler. What are your thoughts on that? Does it make a noticeable difference?

 

I can't wait to get these installed!

 

Since the muffler was tucked up tight, right under the underseat gas tank, I just felt better with a heat shield. I guess it makes a difference as I'm still here. I also made a heat shield for the starter.

Unlike the cheap fenderwell headers I used to have, constantly replacing gaskets, these Sandersons are worry free. No gasket, just high temp RTV. Yes, I did drill those header bolts for safety wire. It's 9 years with any problem at all.

 

This is the kind of review that I was wanting to hear!

 

I picked up a metal blade for my little bandsaw yesterday. I couldn't resist test cutting a bend.

 

Measure twice, cut once.
Cut your way in, weld your way out.

 

I'm already liking these more than the old fenderwell headers!
As expected I have to modify the steering shaft configuration just a tad, but nothing major.





The battery cable and starter wiring will be getting a good quality heat sleeve installed over them. I have a heat shield for the starter as well.

 

Where are you moving your O2 to?

 

I’m still trying to decide that. I need to ask a couple knowledgeable people if I should leave it in one pipe or move it to the merge where it can read both banks.

 

I got started on the drivers side pipe last night.
Here is a little trick for marking out angles and getting square cuts on round bends.




Either these stainless bends are work hardened or the metal blade for the bandsaw is of terrible quality. Either way the zip tie trick is perfect every time!





I sourced some stainless 3/8" thick header flanges from an oddball ebay purchase. All I had to do was cut the old pipe off.




Harbor freight exhaust pipe expander. Use lots of Never seize! I was able to easily expand 2" pipe to 2-1/2" for the flange connection.




Everything is getting tacked together with stainless wire and tri mix gas. This was downpipe tack up #1...... it only took a couple mods to get it perfect.





After a couple break ups and re tacking....... we are pretty much flush with the bottom of the oil pan.
This really is only 2" exhaust pipe. It just seems to grow and grow once you start putting it under a little jeep!