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Novak Headers And Exhaust Pipe Sizing

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

  1. Jul 21, 2021
    jzeber

    jzeber Well-Known Member 2021 Sponsor 2020 Sponsor

    Morgan Hill, Ca
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    Still looking for more pics.
     
    Norcal69 likes this.
  2. Jul 23, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

    Northern California
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    I was so excited to knock this project out...... Got the dreaded backorder email..... :cry:
     
  3. Aug 11, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

    Northern California
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    Parts are starting to roll in for this project.
    Called and talked to Novak... Headers are still on backorder, they ordered another 20 sets to try to get priority with Sanderson.....:cry:
    I have decided to run 2" pipe from the header collectors into a y.
    At the intersection of the y, the pipe increase to 2.25" and run to the muffler.
    The tailpipe will exit the muffler with 2.25" and run out the passenger side rear corner.
    Piping will be stainless. I have stainless wire for my MIG welder..... but hopefully some quality beer will coerce my brother into TIG welding it up for me.
    Muffler is a Walker quiet flow stainless for a Cadillac V8. This system should breathe well within general dauntless operating range while keeping noise to a minimum.

    [​IMG]
     
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  4. Aug 12, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

    Northern California
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    B2259AFA-A525-45DC-BAE2-6C0112C1C730.jpeg A few more parts trickling in. I may have over ordered just a bit, but with current shortages and lead times I want to have plenty of stock on hand.
    I need to order a couple 2” bends and one other special piece.

    [​IMG]
     
  5. Aug 13, 2021
    CJ Joe

    CJ Joe Truckhaven Tough!

    Pinon Hills, CA
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    Nov 9, 2002
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    When I did mine I also went around the front of the oil pan and over the front drive shaft. If you want it up out of the way I don't believe there is any other route. Used a Flowmaster muffler and really like the sound.

    Bought all the pipe from Columbia River Mandrel Bending.




     
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  6. Aug 13, 2021
    Rich M.

    Rich M. Shoe salesman

    Maryland
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    I just saved that page. Slick setup im going that way over the winter.
     
  7. Aug 13, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

    Northern California
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    I have been studying your old exhaust thread quite a bit!
    My latest plan is to mirror your system with the drivers side wrapping to the passenger, Y together, go over the cross member to a muffler and out the passenger side corner. My centered Diff and D20 makes a couple things easier and a couple things harder than a traditional setup.
     
  8. Aug 13, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

    Northern California
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    Just got a shipping notification from Novak on the headers! :bananatool:
     
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  9. Aug 17, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

    Northern California
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    I scored these 3 mandrel bends on ebay way cheaper than summit. They appear to be "2nds" but I don't care.

    [​IMG]
     
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  10. Aug 18, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    A critical part showed up today! It was a bit spendy..... but I think it will be worth it.
    SPD in Rancho Cordova, Ca built this exhaust merge for me. Dual 2" inlets and a single 2.25" outlet.
    I talked with the owner a little bit about my plans and it turns out he is an early jeep guy too! Didn't earn me a discount though... :madwife:

    [​IMG]

    [​IMG]

    [​IMG]
     
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  11. Aug 18, 2021
    Timber Cruiser

    Timber Cruiser Member

    Oregon
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    I noticed you have a heat shield on your muffler. What are your thoughts on that? Does it make a noticeable difference?
     
  12. Aug 25, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

    Northern California
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    I can't wait to get these installed!

    [​IMG]
     
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  13. Aug 25, 2021
    CJ Joe

    CJ Joe Truckhaven Tough!

    Pinon Hills, CA
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    Since the muffler was tucked up tight, right under the underseat gas tank, I just felt better with a heat shield. I guess it makes a difference as I'm still here. I also made a heat shield for the starter.

    Unlike the cheap fenderwell headers I used to have, constantly replacing gaskets, these Sandersons are worry free. No gasket, just high temp RTV. Yes, I did drill those header bolts for safety wire. It's 9 years with any problem at all.



     
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  14. Aug 25, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    This is the kind of review that I was wanting to hear!
     
  15. Aug 26, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    I picked up a metal blade for my little bandsaw yesterday. I couldn't resist test cutting a bend.

    [​IMG]
     
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  16. Aug 26, 2021
    jpflat2a

    jpflat2a what's that noise?

    Riverside CA
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    Measure twice, cut once.
    Cut your way in, weld your way out.
     
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  17. Aug 26, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    I'm already liking these more than the old fenderwell headers!
    As expected I have to modify the steering shaft configuration just a tad, but nothing major.

    [​IMG]



    The battery cable and starter wiring will be getting a good quality heat sleeve installed over them. I have a heat shield for the starter as well.

    [​IMG]
     
  18. Aug 26, 2021
    Steve's 70-5

    Steve's 70-5 Active Member 2020 Sponsor

    Louisville, Ky
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    Where are you moving your O2 to?
     
  19. Aug 27, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    I’m still trying to decide that. I need to ask a couple knowledgeable people if I should leave it in one pipe or move it to the merge where it can read both banks.
     
  20. Aug 27, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    I got started on the drivers side pipe last night.
    Here is a little trick for marking out angles and getting square cuts on round bends.

    [​IMG]


    Either these stainless bends are work hardened or the metal blade for the bandsaw is of terrible quality. Either way the zip tie trick is perfect every time!


    [​IMG]


    I sourced some stainless 3/8" thick header flanges from an oddball ebay purchase. All I had to do was cut the old pipe off.

    [​IMG]


    Harbor freight exhaust pipe expander. Use lots of Never seize! I was able to easily expand 2" pipe to 2-1/2" for the flange connection.

    [​IMG]


    Everything is getting tacked together with stainless wire and tri mix gas. This was downpipe tack up #1...... it only took a couple mods to get it perfect.


    [​IMG]


    After a couple break ups and re tacking....... we are pretty much flush with the bottom of the oil pan.
    This really is only 2" exhaust pipe. It just seems to grow and grow once you start putting it under a little jeep!


    [​IMG]



    [​IMG]


    [​IMG]
     
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