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Novak Headers And Exhaust Pipe Sizing

Discussion in 'Early CJ5 and CJ6 Tech' started by Norcal69, Jul 17, 2021.

  1. Sep 4, 2021
    Dandy

    Dandy Member 2020 Sponsor

    Estherville IA
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    Just a question.....

    How do you plan on welding all the joints, and keep the pipe from moving....:confused:

    My luck, it would be a 1/2' off.....
     
    Norcal69 likes this.
  2. Sep 4, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

    Northern California
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    I’m going to bolt some box tube across the header flanges at each down pipe to keep the spread the same. The 3 v band clamps and flex joint should be pretty forgiving when it comes to reassembly. TIG welding should distort less than MIG welding.
     
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  3. Sep 4, 2021
    Dandy

    Dandy Member 2020 Sponsor

    Estherville IA
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    Looks like learning TIG welding is on the LOOOONNNGGG list to do.....
     
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  4. Sep 5, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

    Northern California
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    With the muffler hanging it was time to work from back to front.

    [​IMG]


    Something fancy is going to happen here. Little hint.... I'm planning on never smashing my tailpipe into the body ever again.


    [​IMG]


    Its hard to see in this pic, but the small pie cuts were necessary to get the tailpipe routing just right.


    [​IMG]

    [​IMG]

    There is a bunch more to do here but that can take place after the exhaust is fully welded. Lots more to come.

    [​IMG]
     
    AKjeff, homersdog, Twin2 and 2 others like this.
  5. Sep 5, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

    Northern California
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    I have been wanting to widen my rear cross member out for some time. This all worked out perfect!

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     
  6. Sep 6, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

    Northern California
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    I have a couple small things to clean up (ugly tack welds, and a few pipe fit ups that aren't quite centered)..... but then we are ready for finish welding :bananatool:
    I have some 5/16" stainless rod on the way to build the hangers out of. I will mig weld those on in place during reassembly. My plan is to have 3 hangers, one pre muffler, post muffler and near the tailpipe exit location. I was hoping to sneak an electric exhaust cut out into the system but I was unable to find a convenient location to do so, and the main priority was a free flowing quiet system. I cannot wait to hear how it sounds! The muffler is factory for a 4.9L Cadillac V8 it should be pretty quiet at low RPM.


    [​IMG]


    [​IMG]
     
  7. Sep 6, 2021
    Twin2

    Twin2 not him 2021 Sponsor 2020 Sponsor

    Virginia Beach, VA
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    shop help is laying down on the job :lol:
     
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  8. Sep 6, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    Dog is exhausted.... :rofl:
     
  9. Sep 7, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    Posting this just for Dandy!
    The headers came with some mild steel flange connectors that were functional..... but really ugly. I bolted them to the down pipes and tacked some random box tubing between them. This should locate the two down pipes during welding. Hopefully it will be all welded up by Thursday for a weekend of reassembly!

    [​IMG]
     
  10. Sep 8, 2021
    Rozcoking23

    Rozcoking23 RUN & GET BIT!

    Stockton, CA
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    This looks great!
     
  11. Sep 12, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    Passenger side starter clearance with new mini starter. Shouldn't have any heat soak issues.
    These headers are so darn shiny its hard to take a decent picture.

    [​IMG]


    Passenger side header is finally installed with silicone!

    [​IMG]
     
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  12. Sep 13, 2021
    zinertia2

    zinertia2 "and which part are you keeping?" 2021 Sponsor 2020 Sponsor

    Greencastle , IN
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    Did you follow these instructions?
    Cure over night or ?
    1. Place a bead of Permatex® #82180 Ultra Black® Silicone (or compatible) at least 1/8" thick, maximum 1/4". Allow the silicone to set several hours or overnight.
    2. Put the header into place. Install all header bolts finger-tight, the torque to 15-20 ft/lbs. Tighten each with a short box-end wrench.
    3. Then the odd comment as. #9 - Permatex® Ultra Black® cures fully in 24 hours at room temperature. We recommend a minimum of 4 hours curing time before firing your engine
     
  13. Sep 13, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    It will be a couple more days before I fire the engine. Well, I may give her a lil open header fire up just to remind the neighbors that I'm still here. :sneak:
    I used Permatex copper. It has a 700 degree temp rating versus the black which only has a 500 degree rating.
     
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  14. Sep 13, 2021
    Twin2

    Twin2 not him 2021 Sponsor 2020 Sponsor

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    yep . got to do it at least once in a while :D
    but dawg wasn't impressed the first time I did it
     
  15. Sep 15, 2021
    Rozcoking23

    Rozcoking23 RUN & GET BIT!

    Stockton, CA
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    Nice work Kyle.
    Now that you have it all figured out,when
    Can I pick mine up?
     
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  16. Sep 15, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    :D You never know with me. I’m liable to run this setup for a couple years, then go all out….build stainless headers from scratch and a whole new system :crazy:
     
  17. Sep 15, 2021
    timsresort

    timsresort Member 2021 Sponsor

    South Lake Tahoe CA
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    I just got caught up with this, things have been really hectic around here. Really nice work! I have done some exhaust work, and I know how tedious the up-down, in-out, tack-cut-weld-repeat program is. I have always said that exhaust in a jeep is a series of compromises, but I think you have found a good route. And nice to know those Advance shorties are worth it. And I am a big fan of the through-the-crossmember tailpipe. A nice Rubicon veteran touch.
    Tim
     
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  18. Sep 16, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    Thanks Tim!
    I actually have just a some more fun planned for the exhaust exit.
    More to come.
     
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  19. Sep 16, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    Here is how I ended up routing the steering. You cannot see in the picture but there is a finger width in between the header and double U joint, Plenty of room for flexing without contact.
    I'm not super happy with this setup but it will work just fine. I could not get it any better unless I moved the steering column position which opens many more cans of worms. :shrug:
    Someday I will reroute the PO's brake line maze.

    [​IMG]

    [​IMG]
     
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  20. Sep 17, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    Just because…….
    It’s not as loud as I thought it would be.

     
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