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Custom Exhaust Installation - Sweet Pipes

Custom Exhaust For The Roadster Pickup
By D. Brian Smith
Photography by D. Brian Smith
Custom Exhaust Installation

Custom Exhaust Installation
As the sign says, Warner's Muffler has been around since 1974.

Custom Exhaust Installation
JBA supplied its Shorty headers for the Ford small-block V-8 and included all the fasteners and collector gaskets.

Custom Exhaust Installation
To assure a perfect seal with the heads, Warner's Muffler utilized Byson gaskets for the 289 to 351W Ford small-block V-8.
Custom Exhaust Installation
Based upon the amount of horsepower and torque the engine produces, Warner's Muffler recommended 2.5-inch-diameter stainless steel pipes and 18-inch Magnaflow Wide Open stainless mufflers.
Custom Exhaust Installation
Jim tightened the header bolts on the driver side and repeated the same process for the passenger side.
Custom Exhaust Installation
By holding up an X-pipe under the faux driveshaft where it would have to go, Jim convinced us we'd be better off leaving it out of the exhaust system.
Custom Exhaust Installation
Before bolting the JBA headers to the engine heads, Jim sanded the bolt surfaces smooth.
Custom Exhaust Installation
To simulate where the pickup's driveshaft would be, Jim cut a section of 2.5-inch stainless pipe and duct-taped it into place between the trans yolk and the differential yolk.
Custom Exhaust Installation
After eyeballing how long the initial pipe should be on the engine side, Jim selected some 2.5-inch-diameter stainless pipe stock and started bending it in the exhaust tubing bender.
Custom Exhaust Installation
Once he'd made the first bend, he test-fit the pipe.
Custom Exhaust Installation
To clearance the oil pan, Jim made several more complex bends in the exhaust tubing bender.
Custom Exhaust Installation
To make the flared pipe ends perfectly round, Jim used the hydraulic expansion finger device.
Custom Exhaust Installation
He used the flare tool to expand the pipe end that mates with the header collector.
Custom Exhaust Installation
Warner's Muffler cut the pipe the desired length in the cold saw.
Custom Exhaust Installation
After more fine-tuning in the tubing bender, the hydraulic flare, and hydraulic expansion finger devices, Jim attached the fabricated pipe to the header collector with 3/8-inch-wide steel header flanges.
Custom Exhaust Installation
Onto the engine side pipe Warner's Muffler fabricated, Jim tack welded the header flanges at each end in order to begin making and bending the next section.
Custom Exhaust Installation
Warner's Muffler used muffler stands to hold the Wide Opens in place for more welding and pipe fabricating.
Custom Exhaust Installation
While Dad watched, Jim made sure the pipes he'd fabricated for going above the half-shafts and through the Kugel Komponents IRS would not interfere with the inboard brakes or the emergency brake on the driver side.
Custom Exhaust Installation
To make the first passenger-side tube, Jim repeated the steps he took to fabricate the driver side. Each side is unique.
Custom Exhaust Installation
With the muffler stand holding the driver-side muffler steady, Jim welded a 3/8-inch-thick steel header flange on the muffler inlet pipe and proceeded to weld the hanger onto the muffler.
Custom Exhaust Installation
Assured that the rear pipes went through the Kugel rear suspension without interference, Jim welded hanger tabs on the rear crossmember.
Custom Exhaust Installation
While Jim held the Magnaflow Wide Open driver-side muffler in place, David laid down more weld on the header flanges.
Custom Exhaust Installation
Notice the Permahold muffler hanger has been partially tack welded onto the driver-side Magnaflow muffler.
Custom Exhaust Installation
Welding the hanger onto the rear pipes came next.
Custom Exhaust Installation
Warner's Muffler blew apart the completed exhaust system and finish welded all the header flanges on the pipes.
Custom Exhaust Installation
Custom Exhaust Installation
The Warner's Muffler custom-fabricated exhaust system is best called Sweet Pipes.
Custom Exhaust Installation
Several days later, we visited Warner's Muffler to see the Olympic Coatings ceramic-coated pipes and Magnaflow Open Wide mufflers, and to witness the whole system going back together.
Custom Exhaust Installation
Custom Exhaust Installation
In no time, Jim and Brian had the custom exhaust system back together.
JBA Performance Exhaust
7149 Mission Gorge Rd., Ste. D
San Diego
CA  92120

www.jbaheaders.com
OLYMPIC COATINGS
Magnaflow Performance Exhaust
Rancho Santa Margarita
CA

www.magnaflow.com
Warner's Muffler

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