I've had a Flowmaster 40 waiting to go on for quite a few months now, and I finally got around to installing it a week or two ago. Up front, I'm sorry I didn't document this better, but hopefully there's enough good pics and info here to be useful to somebody.

DISCLAIMER: If you ever plan on wheeling your rig then this exhaust is not for you. The pipe will get pinched shut if your chassis gets caught on anything. I love my rig too much to tear it up on the trails, so this setup was just what I wanted.

I started by cutting off the old exhaust just in front of the cat, and then cutting it again about where the body mount is (I'll explain that later).


I then broke out the welder and welded everything up. I needed two reducers to get the 1.75" pipe coming off the cat to mate with the 2.25" muffler. While it was off the truck, I soldered up a 1' extension to the O2 sensor.


I then went to work on the hanger. I used the stock hanger and rubber pieces, but hung them from square u-bolts welded to the frame rail.


Now it was time to put everything back on the truck. I cut the pipe at the body mount because, in order to make it exit where I wanted, I needed to remove 1' of pipe, and the pipe was straightest at that point. I reconnected it with u-bolts.


I was pleasantly surprised that nothing was in danger of touching the frame, and was hanging completely free with room to sway. It's very rare that things brake my way when wrenching, so I savored this moment a bit .



I had to get a piece of pipe custom bent to 25-degrees to get the system to exit where I wanted. I coated that and some other pieces with high-temp grill paint.


Then I popped a nice tip on the end and called it good. It's not perfect, I wish the tailpipe was a little closer to the body, but we can't have everything, and I really can't complain about how it looks.

 

looks great

 

looks great, but you're right. If you wheel with a setup like that you'll be totally screwed how's it sound?

 

Nice man, I just put a flowmaster Delta 40 on my rig. I decided to take it out the back instead of the side. I like the way mine sounds.
I posted a sound clip of mine here: https://www.yotatech.com/forums/f116...l#post51522375

 

If you've heard 22REs with Flowmaster 40s on Youtube, then you know what it sounds like, as you would expect. Starts as a deep growl and works its way up to a howl. So far as volume goes, let me put it like this: with the windows up, I can listen to the stereo without a problem. If the windows are more than half-way down, forget it, all I'm gonna hear is that engine roaring !

So in short, not as nice as yours, but I'm happy!

 

I wheel that setup on my 92. Sounds nice with the v6. I agree its not good. Mines only clamped to the back a universal cat, exits right at the frame by the spring bracket, and never even worried about pinching it closed. However it does hang really low there. Mine has MANY scratches and dents, even ripped it off once on a tree stump. But you know what they say..adding a 40 is like adding a skid plate. Next time im running it up through the bed stack style....

 

i have a flowmaster 40 in the stock location on mine and i can def wheel it without damaging anything, but the way you set yours up i agree with your comment

i cut my cat off and put a straight pipe in there and i thought it made the flowmaster actually sound like i had some what of an exhaust, before it sounded stock
(i may, unintentionally, be comparing it to my camaro which is why i think its so quiet)