In the world of Custom Classic Trucks the vehicles representing the genre are as the name implies: custom. When hearing the word "custom" and "truck" together the first thought that goes racing from the left to right lobe of the brain is appearance. However, what lies under the scathed or unscathed sheetmetal needs to be appealing as well.
Nowadays it's the norm to alter the truck's chassis. Let's face it; finding stock underpinnings beneath vintage sheetmetal isn't common ground among our crowd. Instead, what we find are owners updating their trucks with various types of running gear to ensure their truck is not only safer but more driveable. With all the suspension, engine, and tranny options throughout the CCT world one can set up their truck for drag racing, cruising, long hauls, hauling, and the list goes on. For that reason, many stock parts just won't cut it, including the exhaust. Unfortunately, exhaust pipes can't bend and twist like a radiator hose or pipe cleaner, and because of it stock exhaust systems-or stock configured systems-won't meander through all those various extra-special chassis components. For these instances, a custom exhaust system is the only answer.
One way to alleviate the problem is to drop your ride off at a muffler shop and have them create a one-off system. The other is to take matters into your own hands and order a DIY kit, which suits folks like us quite nicely. One company that offers everything needed for an exhaust system is Stainless Works. Stainless Works manufacturers everything from header collector diamonds to mufflers, hangers, bends, bolt-on exhaust systems ... literally everything! Not only does Stainless Works offer up everything from A to Z, but they take the necessary steps to offer only the finest products. As the name implies components are constructed from high-quality stainless steel and they are manufactured using techniques such as mandrel bends, laser cuts, and TIG welding. All in all Stainless Works offers high-quality exhaust pieces to outfit your system in any way, shape, or form.
This dilemma presented itself for Project Get Shorty. The abundance of foreign products nestled below Get Shorty equal the number of obstacles D-list celebrities must overcome on VH1's Celebrity Fit Club! To tackle the beast we ordered a Stainless Works DIY Rod Builder Kit. Stainless Works offers various OD-sized kits, and the option of a butt-weld or slip-fit connection. We chose a 21/2-inch butt-weld kit. The kit comes with all the bends necessary to navigate most any exhaust route. All the tubes are 18-gauge (0.049 wall thicknesses) 304 stainless steel with mil-spec certified USA manufactured tubing. All ends are also OD-sized for easy welding. They also offer various styles of mufflers, including chambered, turbo, round, rap trap, and more. What suited our fancy were the polished Smooth Oval mufflers. The mufflers feature 21/2x41/8-inch bodies with an overall length of 24 inches. They have a unique design that allows users to use one of the two available 21/2-inch exhaust inlets. One of the inlets provides a mellow note while the other gives a more aggressive note. Like the tubing, the mufflers are 304 stainless steel throughout. Completing our system are hangers and tips. Stainless Works offers various styles of hangers and tips to accommodate an individual's "custom" needs. In our case, we ordered several styles of hangers and a set of polished turn-down tips. By the way, Stainless Works can make a set of custom tips for whatever application you desire. Just send them the specs and your wish is their command. Way cool if ya ask us!
Here's what we're working...
Here's what we're working with, a 21/2-inch Stainless Works DIY Rod Builder Kit. The kit comes with a variety of tubes: four straight tubes, four 90-degree elbows, four 45-degree elbows, and four U-bends. Along with the kit we also ordered a set of polished oval mufflers, polished turn-down tips, a set of header collectors, and hangers. If your project requires more bends you can order them separately. A "grab bag" of bends containing random angles and lengths can be purchased as well.
Before we could get started...
Before we could get started working towards point B, we needed a point A; with point A being a set of Doug's Headers. Even though Get Shorty sits only inches off the ground, the high-and-tight tuck of the headers allowed us to use a set of Tri-Y long-tube headers. The headers come complete with mounting hardware and the proper gaskets.
The first step was to use...
The first step was to use an appropriate gasket sealant on the supplied gaskets. From there the gaskets were aligned for fitment.
Next, the Doug's Headers were...
Next, the Doug's Headers were installed. We were able to drop the passenger-side header in from the top, but the driver-side header needed to come in from below.
The good news is that the...
The good news is that the headers tuck up tight and run parallel with the frame. The bad news is that once the Stainless Works header collectors were mounted they're in a direct line of sight with the tranny crossmember. (Note arrow.)
When it comes to routing exhaust,...
When it comes to routing exhaust, whatever works ... well works! (Be sure to steer clear of hoses and brakes lines, and allow at least a 1/2-inch of clearance between neighboring objects.) Therefore, we studied the various tubes in the Stainless Works kit and figured out a solution. I found that if I shortened one side of each of the 45-degree tubes I could weld them together to form an elongated "S," which will dodge the tranny crossmember.
I started off by shortening...
I started off by shortening the collector and 45-degree tubes. There are multiple options for cutting exhaust tubing; I chose to use a 6-inch cutoff wheel.
Being that the cutoff wheel...
Being that the cutoff wheel is a handheld tool, it was a little hard to create a perfectly straight cut. In order to square things up, or add a bit of angle to a cut, a 7-inch grinder was put to the task.
Stainless Works offers two...
Stainless Works offers two styles of kits; one is the butt-weld kit while the other is a slip-fit kit utilizing clamps. We choose to go with a butt-weld kit. Whichever way you choose to weld up stainless tubing one thing is for sure, you must use stainless filler rod. If not, the tubes will retain their natural color while the welds slowly rust away. I choose to TIG weld the exhaust together with ER-308 rod.