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Novak Headers And Exhaust Pipe Sizing

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

  1. Aug 30, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

    Northern California
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    Yes. 3 bolts on each collector and a V band clamp at the merge.
    Removing the oil pan is hopefully an infrequent enough occurrence that it is not bothersome to remove the Y pipe in order to access it.
     
  2. Aug 31, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

    Northern California
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    Passenger side down pipe.

    [​IMG]

    [​IMG]

    Drivers side down pipe.

    [​IMG]

    [​IMG]

    Both down pipes headed for the merge.

    [​IMG]


    I'm hoping to get both pipes routed into the merge tonight. So far the lowest point is flush with the bottom of the oil pan, everything else from there on is flush with the bottom of the frame.
    The starter will be getting a 3 layer shield to prevent heat soaking. I imagine that there will be a couple other heat shields in special locations.
     
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  3. Aug 31, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    If the starter clearance proves to be a problem, I have found a solution!
    I stumbled upon a stock style mini starter offered by TA Performance. A little reverse P/N looking up lead me to Powermaster P/N 9202
    This starter fits a variety of 80's and 90's GM vehicles.
    I may go ahead and install this new smaller starter just to pick up some room under the engine.



    [​IMG]


    The TA Performance is the chrome version that Powermaster offers.


    [​IMG]
     
  4. Aug 31, 2021
    timgr

    timgr We stand on the shoulders of giants. 2021 Sponsor 2020 Sponsor

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    I like the iridescent plating better. They are probably both zinc.
     
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  5. Aug 31, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    The power master version is $100 cheaper than the TA version. Both have upgraded steel gears. Factory versions are plastic.
     
  6. Sep 1, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    More progress.
    Drivers side with extension toward the merge.

    [​IMG]



    [​IMG]


    [​IMG]

    [​IMG]
     
  7. Sep 1, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    My work light ran out last night while I was finishing up. Here are a couple better perspective pics from this morning.

    [​IMG]

    [​IMG]
     
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  8. Sep 1, 2021
    jzeber

    jzeber Well-Known Member 2021 Sponsor 2020 Sponsor

    Morgan Hill, Ca
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    I went from P side to D side on mine. I did have contact with the diff once or twice on the P side down pipe. Hopefully yours is not too close.
     
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  9. Sep 1, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    On yours it looks like your pipe went straight around to the drivers side? Hopefully the hump in mine will allow plenty of clearance.
    I'm pretty sure that everything will clear. Of course a Forklift flex test will be conducted before everything is finalized.
     
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  10. Sep 1, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    Here is the final iteration. I moved the merge forward about 2". This will allow me to locate the o2 sensor in the merge at the same distance it was in the old fenderwell header. This time however it will be reading both banks.
    From the merge we will start off with a V band clamp, then a 4" braided flex section, before diving into the frame rail to pass the transfer case.

    [​IMG]
     
  11. Sep 1, 2021
    4S50

    4S50 I’m back! 2021 Sponsor

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    That is art! Well done:clap:
     
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  12. Sep 2, 2021
    AKjeff

    AKjeff Member 2021 Sponsor 2020 Sponsor

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    Agrees, that is some real nice work Kyle.
    I was just telling my wife, I don't have the patience or attention span for that kind of work.
     
  13. Sep 2, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    Thanks guys! It is actually turning out to be pretty fun so far.
     
  14. Sep 2, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    Today's update.
    o2 sensor bung is tacked in, V band clamp is tacked on as well.

    [​IMG]

    [​IMG]


    Taking off from the merge I threw a 1" section of pipe on with the other half of the V band and a 4" long flex section to help with vibrations and frame twist.


    [​IMG]


    From here we are ready to travel past the transfer case.


    [​IMG]
     
  15. Sep 2, 2021
    jzeber

    jzeber Well-Known Member 2021 Sponsor 2020 Sponsor

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    Much nicer than the way mine turned out! :beer:
     
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  16. Sep 2, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    Mine is a little out of control. :rofl:
    This is what happens when you have a couple IPA's and spend so much time staring at the bottom of your jeep that you fall asleep. At least the concrete is nice and cool. :shrug:
     
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  17. Sep 3, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    Last night's progress.
    I got the mid pipe all tacked together. After the flex section the pipe bends out toward the c channel frame for plenty of clearance around the transfer case.
    One of my biggest concerns about the inside frame exhaust system vs the outside frame system was ease of working under the jeep. Up till now I have done transmission, transfer case swaps and been able to drop the cross member without ever removing the exhaust system. I believe that this system will still allow me to do everything as before with the exception of the oil pan. In the event that I do need to get the exhaust out of the way, it will be simple thanks to the V band clamps.

    [​IMG]
     
  18. Sep 3, 2021
    Twin2

    Twin2 not him 2021 Sponsor 2020 Sponsor

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    that's a pretty slick pipe bending machine you got there :D
     
  19. Sep 3, 2021
    Keys5a

    Keys5a Sponsor

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    Beautiful work. This might inspire me to get back to work building the exhaust in my AMC 360 powered LR D90!
    -Donny
     
  20. Sep 4, 2021
    Norcal69

    Norcal69 Out of the box thinker 2021 Sponsor 2020 Sponsor

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    Finally the muffler is hanging!
    The midpipe ducks in the frame rail to provide adequate clearance for the transfer case. The Arb line in convoluted tubing running through the frame rail will get rerouted away from the heat.

    [​IMG]


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