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Past Bronco Owner
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4,856 Posts
Discussion Starter · #1 · (Edited)
Since I bought the Bronco I always had low power at the high end and suspected it was the catalectic converter

I recently ordered a Bassani Y-Pipe with a high flow cat. When they arrived I started pulling apart my old exhaust and opened up the cat to see what was inside. My suspicions were right.



I previously installed Summit shorty headers and will leave that part out but just so you know, they are there. I spent a few hours cutting our the old exhaust. It fought me all the way. The worst was a completely rusted u-bolt on the return flow tube the is above the cat and hard to reach. I ended up using a Dremel and about 8 cutoff wheels. I couldn't find the good fiber ones so I just kept braking the cheap ones until I cut through the u-bolt. I also had one of the bolts between the shorty headers and old Y-pipe locked on so bad I had to cut it in half.

Getting the Bassain Y-Pipe wan't fun either It just would nor cooperate. I finally did manage to get it in place.



The cat slid right in place. They included two stainless clamps to hold the cat and muffler in place.



The Flowmaster Super 40 was 2 1/4" in / out so I used a piece of 3" exhaust pipe and cut the opening to fit.



I ordered a 3" mandreal U bend from Jegs and cut in half to make two l bends. I also cut 8" off the pipe between the muffler and the cat.



I had to cut a little sheet metal to get it to exit out the corner of the wheel well. And out the side it goes. the piece I cut off the cat end fit nicely at the end.



Ta-Da!



I added a bracket to the tail pipe.

 

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Past Bronco Owner
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4,856 Posts
Discussion Starter · #3 ·
Rubber would melt pretty fast. I'm going to look for a metal ring the right size and fab up something flexable to go between the pipe and ring.
 

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Practicing Infidel
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15,299 Posts
Looks very nice 90Beater

Did that 2 1/4" Flowmaster muffler still work after you and the 3" pipe had your way with it ???

I like the clear, simple, mandrel bent runs on the tailpipe. Didn't realize the Bassani pipe restricted access to the starter motor so much. Still that must sound great and help your torque immensely.

Well done !

Sixlitre
 

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Past Bronco Owner
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4,856 Posts
Discussion Starter · #5 ·
Oh yeah! The sound is badass. It sounds like a muscle car now. I'll have to figure out a way to make a sound clip.

It feels like I went from a 4 banger to a big V-8 going from the clogged cat to the no drag flow. Boaring the holes on the muffler didn't do to much to it. It's a pretty basic design. There are a couple baffles in it that are pretty much three v shapes that redirect the flow a little. Enlarging the holes only lets more air through.

I previously had the exhaust coming out the side but it was back a little further and just dumped out in front of the tire. Moving it forward 8" lets it go strait out the side like I wanted and I get no fumes with the rear window down.
 

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Former owner of Shadofax
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17,026 Posts
Nice, Chris.

I would pass on chrome tip suggestions. With your whole camo/blacked out scheme, I would try some of that hard black door edge (it's cheap, so if it can't take the heat oh well). Go get a can of high temp BBQ black for the exhaust tip.
 

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Past Bronco Owner
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4,856 Posts
Discussion Starter · #8 · (Edited)
It's loud when you start it up and if you are going up a hill but on even surface it quiets down and the tires take over as far as noise goes. If it was loud at all times I would restrict it more. Even though I drive it like a little old lady on the street I allready attract attention with the paint, It sounds like it looks like it should.

Routing over the frame also protects it off road.

This is why you don't want to mount it under the front leaf hanger.
 

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OMG its almost a
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1,367 Posts
Shadofax said:
Nice, Chris.

.........Go get a can of high temp BBQ black for the exhaust tip.

:thumbup :thumbup I like that Idea, but then you still nedd something to keep it from banging up that hole in the fender right???

How about something like this, where the blue represents some flat stock like 1/8" or something to keep the exhaust in place and not have to worry about it banging up the hole in your fender!!!
Just a thought
 

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Former owner of Shadofax
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17,026 Posts
Routing over the frame also protects it off road.

Yes and no. Where you have it exiting, just as Dustin mentioned that is the one area I always end up with bent sheet metal. Fortunately it's thin metal and you can reach around behind and pull it back out.
 

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Past Bronco Owner
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4,856 Posts
Discussion Starter · #11 ·
If you look close mine is bent a little too but it has a rock slider protecting it now. :thumbup

SoCalFSB: something like that but I will probably hang from over it instead.
 

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FSB Pimpster & Recruiter
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5,714 Posts
Beater, how much was the Y-Pipe? I was thinking of getting the Off-Road one and just going with 3" exhaust.....

Thanx in advance,
Allcruisen :imp :usa

Do you have a link to bassani?
 

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Registered
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9,138 Posts
It also reverberates waay more in the cab with a turn-down. I am really kinda unhappy with my turn-down. It also stirs up a sh*t load of dust in technical, slow places covered in powdery slit type stuff.

I think I'll order up a mandrel bend and run it out the side, but not through the body. Thanks for the inspiration 90, and it sounds badass.

BTW, sounds kinda similar to my straight-through 3" Magnaflow muffler. I'll post a clip if anyone is going between a straight through or cambered type muffler and would like to directly compare the two.
 

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Past Bronco Owner
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4,856 Posts
Discussion Starter · #14 · (Edited)
I bought mine and so have a few others now from performancepeddler.com Aluminized $265.05 (no tax free Fed Ex shipping) with high flow cat.

With the exit out the side I get no fumes with the rear window rolled down, wether the side windows are up or down. :thumbup


The mandrel bent U part # 289-42323 was $19.99 at Jegs.com
 

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Past Bronco Owner
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Discussion Starter · #15 ·
I'm bumping this up since it's been a while since anyone posted to it.

As far as mods go this one definately gave me the most bang for the buck. Over $250 sounds like a lot of money for a y-pipe and cat but once you finally plunk down the cash you will wonder why you waited so long.

Fireguy I could listen to that sound all day long and not get tired of it. Since this writeup I have swapped my motor and now have even more power. I would not want to go back to the stock exhaust.

I would definately reccomend this mod to anyone that was even slightly interested in doing it.
 

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broncofied
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1,475 Posts
Well done beater i appreciate your creativity in some of the things you do differently. Now for my only concern what caused the cat to melt down is there any problem current with your engine that could cause another meltdown or is that a previous issue??
 

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broncofied
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1,475 Posts
Okay and i gotta do it here is mine on some jackstands yes it has a cat by the steam, and the water out the tailpipes 40 series flow 2 1/4, and 3 inch piping ford motorsports shorty headers.

56k no go

 

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Past Bronco Owner
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4,856 Posts
Discussion Starter · #19 ·
MANNY said:
Well done beater i appreciate your creativity in some of the things you do differently. Now for my only concern what caused the cat to melt down is there any problem current with your engine that could cause another meltdown or is that a previous issue??
Old motor had a bad O2 sensor but it doesn't matter now. New motor installed soon after the exhaust was redone.
 
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