Topic: Performance Stainless catback for $160

[sharpxmen]

this is my plan

Magnaflow 14616 Stainless muffler 2.5'' in/out off ebay $73 (i have an offer at $65, we'll see if it gets accepted, if not $73 is actually quite cheap)
BANKS TAILPIPE FOR 04-06 UNLIMITED 52656 (stainless) 2.5'' from AcmeJeepParts $86 (i already ordered this one)

grand total $159 - compare to banks or similar at about $400 for all stainless catback, so it's pretty good imo.

I went with the unlimited on the tailpipe for 2 reasons: cheaper by $20 (i wonder why since it's longer) and I will need to cut and weld anyway since the muffler is round and to have some extra length available (the 14616 muffler is a bit shorter than the stock one).

i want to add a Magnaflow heavy metal stainless cat 2.5''/2.5'' at about $85 (ebay as well)

only downpipe will be at 2.25 but am planning to upgrade that one as well in the future, for now i will just use a reducer.

[sharpxmen]

I decided to go with Magnaflow 14226 which is a 2.5 inlet/outlet 5''x8'' oval shape (stock is 5x10) - all stainless mirror finish. It's a couple of inches shorter than the stock one. Was $80 on ebay with free shipping (just placed the order, takes about 10 days to get delivered as it's dropped shipped straight from Magnaflow. I also ordered the cat for $73 (also stainless), and the tailpipe for TJ unlimited for $86 (stainless and mandrel bent) - all are 2.5'' diameter so that will be a nice upgrade not to mention the free flowing muffler and the cat that is rated for 6.2L displacement (so it should flow better than the generic junk i've been running). Now I need a coupler/reducer from 2.25 to 2.5 and some band clamps (i'm just going to spend the coin on these as the regular exhaust clamps are deforming the pipes and it's a pain to take it apart, i have a band clamp at the end of the downpipe towards the cat and those come apart with very little effor every time if you manage to brake them loose by rotating back and forth a few times).

I'll post some pics once i have them all installed

[sharpxmen]

I started the mockup for the muffler and cat

both have 2.5'' ID at both inlet and outlet (dumb if you ask me) and also the inlet on the muffler was coming out at an angle, so i cut it about 1/2'' from the factory weld and added a 5'' long 2.5 OD stainless pipe (from the LJ tailpipe which is plenty long) so it slides into the outlet of the cat. Used a pre-formed Dynomax band clamp to join them together straight on both planes (they are 0.6 deg off which i find acceptable, will probably need to get them in the final position when on the Jeep anyway).

I also had to weld a reducer 2.5'' ID to 2.25'' ID at the muffler inlet to be able to mate it to the 2.25 downpipe.

Need to check the fit under the Jeep in the next few days.





the Banks 2.5'' LJ tailpipe will require some cutting and welding (on my '95 YJ) so i don't recommend it unless you can weld stainless, it has nice mandrel bends and it's huge compared to the stock kink-bend pipe.

I'll update with more pics as I get things done.

[grumpygy]

Should try to get a Pic of mine.  Since I have the header on it was just a Bolt up if I got the 92 year cat.  Muffler slipped right into the cat and the tail Pipe slipped right into the Muffler.  Band clamps on them too and all is good.

[sharpxmen]

Muffler slipped right into the cat and the tail Pipe slipped right into the Muffler.  Band clamps on them too and all is good.

that's what is supposed to be like, not sure why magnaflow has both in/out at 2.5 ID - but for me worked better since the inlet was not straight out but at an angle (manufacuring defect) so I would have had to cut it anyway or return it and wait another 2 weeks for a replacement - no big deal here but not a bolt-on solution. The 2.5'' diameter and all stainless makes it worth for me though.

Another thing i am planning to do before installing it all up there is to get some better thermal insulation for the floor - the factory heatshield is just above the muffler, in the FSM i saw a bolt on heatshield for the cat as well but i have yet to see one at a junkyard so I will do 2 things:

1 - will make a heatshield similar to the one above the muffler for the cat there is a rib on the tub where the factory heatshield is bolted on with 4 screws, this rib continues above the cat as well so my plan is to make a shield out of 20 ga stainless to go there.

2 - use fiberglass mat (double sided aluminum) above both the factory heatshield and the new one to reduce the heat transfer - the floor is getting ridiculously hot down there on long trips, i need to address this issue.

[grumpygy]

I wondered about the heat shield Mine is just above the Muffler just as yours is.  I did add a sound barrier which also acts as a heat shield.  Just not sure if it will be enough.  Please post if you do find a heat shield for the cat.

It would be nice if that shield also went down between the Cat and the Transmission.

[sharpxmen]

I'll post some pics once i have something going. Plan is to have it curved (bent actually) around the cat about 1/3 or 1/2 down (similar to the stock heatshield above the muffler) but it won't be a screen between the cat and transmission though.

[andpgud]

It would be nice if you could add a picture of the whole thing along with headers.
Would there be any gain on a 2.5 with a exhaust like this and headers?

[grumpygy]

It would be nice if you could add a picture of the whole thing along with headers.
Would there be any gain on a 2.5 with a exhaust like this and headers?

Just as I was told, Did not really Notice any change in the low end, But now have some nice passing ability.  Down shift to 4th and I can now pass at 55 -60 MPH.  Could not do that before.  Hills do not bog me down as they did before.

[andpgud]

That sounds actually pretty good. If I would add a TB with spacer that is 62mm and a exhaust with a sport cat and headers I would be going in the right direction.
Pretty hard for me to get a magnaflow for a reasonable price here in europe.

[sharpxmen]

That sounds actually pretty good. If I would add a TB with spacer that is 62mm and a exhaust with a sport cat and headers I would be going in the right direction.
Pretty hard for me to get a magnaflow for a reasonable price here in europe.

all you need is a center/offset muffler that is 4''x10'' or 5x8 or in between (4.5 x 9 for example) - any of those would work, there a plenty of options in EU for performance mufflers. Just make sure you match the piping diameter or weld adapters worst case scenario. the bigger problem would be to get the mandrel bent tailpipe over there imo, probably you'll need to fab it from pre-bent tubing.

[grumpygy]

You sure about that rib from Muffler to the cat.  Mine ends right at the end of the muffler.

[sharpxmen]

You sure about that rib from Muffler to the cat.  Mine ends right at the end of the muffler.

mine goes all the way above the cat, i'll take some pics - maybe we talk about different things.

[sharpxmen]

cat and muffler test fit


you can see the rib going all the way above the cat

[sharpxmen]

Tailpipe work - like i said, i don't recommend it, the LJ tailpipe is different than the YJ above the axle, so i had to cut and weld it back together. Luckily I ordered the LJ and not TJ so i had enough length to play with.

This is what i started with


And after lots of cuts, welds and fitting under the Jeep i got it like this






and this is all done, welded and sanded


Of course i messed up 1 spot that took hours to fix, i tried to fill it with welds and then i realized it keeps sinking in and cant fix it so i cut the mess out and patched it with another piece of pipe i had left








Test fit on the Jeep








all good, need to weld the hangers to the tailpipe now and should he good to go (once everything else is done of course).