[Ironclad]

I've seen a few grumblings in various threads on the FSB forum from other Virginia Bronco (and a few other) owners reguarding exhaust and emissions laws in the Old Dominion State.

I recently rebuilt and installed a 302 HO out of a 93 Mustang. Changed the cam to one more suitable for the low end power that Bronco's crave. Added a few other bolt on performance goodies including a set of shorty headers off of a 93 Mercury. Now what I needed was a good dual exhaust system!

Canning the cat is sure way to not pass Virginia state inspections. In addition it can also negatively affect the truck's performance not to mention the detremential effects to the atmosphere.

Since I do not have the equipment to fabricate a custom exhaust, the search was one for a good price for true dual exhaust from a local shop.

Every shop I contacted in my area (south east Virginia) stated that they could not do the job since it involved altering the factory emission system. Even though I was going to be using two catalytic converters instead of one, the answer was still NO.

I found a shop down in Elizabeth City, NC that could do the job for what ended up being a fair price (at least in this area). The upside was, that even though a VA shop will not do the work, the truck will pass Virginia state inspection with a true dual exhaust system as long as there are catalytic converters installed. (Assuming they don't notice that missing smog pump thingy? :shrug )

I think as most of us know, it's a pretty tight fit up under a Bronco. There's not a lot of area to run a dual exhaust system so the fit has to be fairly precise.

The run coming down off of the drivers side header curls down and over to the passenger side tight up under the bell housing.

The passenger side was mostly a straight drop down heading towards the back between the starter and the frame. A new O2 sensor socket was fabricated and welded into the pipe.

The mechanic installed the pipes "over and under" fashioned. They run back between the transmission and the frame up over the transmission mount and drop down towards the skid plate where there is room to install the cats and the mufflers.

I opted for two CatCo high flow converters. The write up on them from Summit says:

Since you have to use a catalytic converter anyway, you might as well use one that's going to last a long time and maintain your vehicle's performance level in the process. This converter not only outflows the stock converter, it features aluminized dual steel heat shields, 409 stainless steel shells, 16-gauge stainless steel pipes and nipples, and a heat resistant sealed mat, all of which help the converter last longer. This converter has a steel air tube with perforated holes to help distribute the air flow evenly without robbing power.

2 Catco CTO-6005 catalytic converters - $110.00

Like I said.... it's a tight fit up in there for dual exhaust and I was very impressed with how the guy installed the pipe runs.

A short run after cats come the mufflers.

When I got it to the shop, they asked me how I wanted the truck to sound? I replied not to loud but certainly "throaty."

The issue here again is space. The mufflers have to fit between the frame and the drive shaft. They reccomended a set of Flowmaster Hushpower II's because they are "tubular" instead of the traditional box and would fit with a lot less chance of ever hitting the drive shaft.

I agreed, but they didn't have them in stock. Since this is my daily driver, I couldn't leave it at the shop for the three days it was going to take to get them (holiday and weekend). So I opted for a "generic" version of similar flow and quality.

2 Hi-flow mufflers - $45.55

After the mufflers, the pipes turn back up to go over the rear end and branch out towards the left and right behind the rear tires. I opted for this set up instead of straight back so I'm not choking on exhaust fumes when I'm riding around with the rear window down.

The pipe size is 2 1/4" because bigger is not always better. To big and you can actually end up losing performance.

All total with the two cats, mufflers, pipe, fittings, hangers, and labor the job cost me $410.00. I didn't think that was to bad considering I've seen "cat back dual exhaust" systems selling for $250 - $300! And that's just the parts.

Once I fired that sucker up.......

Man Oh Man! :thumbup

She growled oh so nice! I mean it did sound a little loud still, but hell! I'd been driving it for 3 days on mostly un-capped headers. So it was quieter that what I was used too.

Now that I've had it for a while, I would have opted for mufflers that were a little quieter. But since I've got it... I'm learing to love it. Once the novelty of the sound wears off, I will be able to figure out what my gas mileage is since the rebuild. Right now I just can't seem to keep my foot out of it... :chili:

~THE END~​

 

[rem_243]

Looks nice. Are those about 14" packs? That's about the same setup I have, except withouth the cats. Once again, looks good.

 

[Max]

That's a nice setup you've had done there. Not queer like big straight pipes out the back under the bumper so you suck fumes back in the truck. Those look like Moroso Spiral Flow mufflers....?

 

[Ironclad]

:shrug They're spiral flow, but I do not know what brand? They just brought em out and put em on. No brand markings on the tubes anywhere i could find.

I like them, but I think when they wear out, I'll opt for something a little quiter. Since I've had this system put on.... I don't know if I'm just being a little paranoid or what?..... but the cops seem to watch me go by a lot more often that what I used to notice?

 

[Max]

I do have a Moroso spiral flow muffler, and I'm quite content with it on the truck. Been on now for about 20K miles, and has a good sound that's not too loud. They're really not a bad muffler at all.

 

[fordman7795]

ive got the cherrybomb glasspacks in a straight dual exhaust too. no cats and sounds nice. cops havent pulled me over either so it must not be that loud.

 

[Drilim]

I had a flowmaster delta series put on back in June. Love the sound, Its a single in, dual out to 3.5 inch tipes just before the rear panel ends. It looks good, Stays out of the way and flows awesome. I had this before my K&N and did honestly notice about 2 mpg increase over all. Once the mufflers break in, It will get deeper and throatier as opposed to just loud. Looks like he did an awesome job running the pipes tho.

 

[Fireguy50]

How did they route the exhaust past the rear brake line????????????/
That is my constant complaint with duals, too close to the brake line right near the gas tank on the drivers side.

Get me a pic of that spot

 

[Tomh971]

do you have 1 or 2 oxygen sensors????

 

[Fireguy50]

you talk'n to me? I ain't got O2 sensors

 

[Tomh971]

oh, my bad.... it was directed at Ironclad...

there are ways to get around things... things ya learn as a 'Stanger....

and yes, the '95 GT is for sale...

 

[Ironclad]

There's just one O2 sensor Tom.

I went out and looked at the driver side pipe and you called it Ryan.

While I don't think it is too close to the gas tank, it is most definetly bad for the left rear brake line. See pic. If the weather cooperates this weekend, I'm going to have to refit the line and potentially add some sort of heat shield?

I was so enamored with the shiny cats and mufflers I looked right past that on the visual tour on the pipe run.

Thanks for the heads up...... Jeff

 

[Fireguy50]

SEE! I hate that $h!t!
My dual was like that, but they put some of the green silacone hose over it. the stuff they use for exhaust smog pump hook up. I never liked the dual set up because of that problem.

I got ripped off by a Minake $550 for a complete dual set up.
Y into one cat, into one muffler, then split into duals out the back.
I cut it all off 2 months later. I'm still pissed

 

[gearrat]

looks good

 

[Stokes]

in everyones thought on how they routed their dual exhaust might as well show ya how the shop did mine. when he was lining it all out i forgot to mention that i wanted clearance, becasue i had already bugged the guy about putting everything in place so i can still easily drop the tranny (i new it was bad and had not removed it yet) i paid around 450 for all piping and the flowmasters, then the catco's cost me about another 100.

overall i am preaty happy with the setup, i think the crossover around the T-case is alittle low but i have yet to drag it so whos complaining!

 

[Stokes]

oh yeah and about the brake line issue, i looked at mine a second ago to check, and he routed my exhaust so its about 3-4inches away from the brake line and about 1-2inches away from the gas tank. pleanty of clearence for me.

 

[Fireguy50]

well take a picture of it for us

 

[85f150]

hey i have a question....since i am getting ready to drop in my 351 how am i going to run duals....i have dual tanks so i would not be able to split over to the passenger side until the rear axle...or i could just run both of them out the passenger side like some older disels...??????? :brownbag

 

[Ironclad]

Now that looks good Joey. I wish my thought to ask the guy to run mine so that it cleared more of the transmission. Now that I've got that nice new engine in, my AOD is starting to act up!

85f150...... Since the dual tanks are an issue, I think your suggestion of runing them both out on the passenger side is a good option. I worked with a guy who had an 87 F-250 with dual tanks. When he had duals installed that's the route he took. I do remember it being a custom job and that always kicks the price up. I paid $410.00 for my system which was an all custom fit and I got my money's worth.

I considered runing both of mine out the passenger side, but opted for the left and right split with the over/under set up the guy did on mine. And of course I didn't have that second tank to get around either.

Oh yeah.... Truck Porno my @$$!

Man... that's a sneaky way to get traffic to your profile page! :lowblow

 

[NDIXIE]

My 95 has two cats and one O2 sensor. The first cat is part of the Y pipe. When I bought the Bronco it did not need an emissons test. After about a year it was time and would not pass. Checked everything and come to find out both cats were punched. I was going to replace them, but I could not find anywhere that sold the cat except the stealership. So I just got the second cat and it past.
I said all of that to ask; is there anyway I could get rid of the first cat legally? I realy don't like the punhed out cat makes my exhaust sound.