CJ-7 Projects


Lightforce Lights - H.I.D. High-intensity discharge Upgrade

HEI Ignition System (GM Style) Installed in the AMC 360 V8
Getting rid of gremlins and improving performance

Installing 23,000 Volt Offroad Lights

Autogage Tachometer Installation

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 Centralia PA
Project CJ-7
Offroaders Guide
to Gearing up
for Offroad

From Basic Equipment to Well Equipped.  An extensive list guide to help you prepare your vehicle for the offroad.


Onboard Air
Converting a York
AC Compressor
to Pump Air

Trailering Safety and Trailer Hitch Information


Off-Road Truck Driving Techniques and Safety

Off-Road Lights
by LightForce Product Review / Installation.
from Off-Road Lights


Jeep Dana 300 TeraLow - 4:1 Gearset for the Dana 300 Transfer Case

AMC V8 Engines
GEN-1 Nash/Hudson/Rambler V-8s (1956-1966) through to the GEN-3 AMC Tall-deck (1970-1991)

Chevy Small-Block V8 Engines
Chevy Small-Block V8 Engines Manufactured by General Motors - Production: 1955?2002

Hemi Engine - All about the Hemi Engine

Ford Engines
4 Cylinder, 6 Cylinder, 8 Cylinder, 10 Cylinder, 12 Cylinder Ford Engines

Ford V8 Engines
8 Cylinder Engines manufactured by Ford

Ford 351 Cleveland V8 Engines
351 cubic inch V8 Engines manufactured by Ford

Chrysler Hemi Engine

AMC V8 hp/Torque, Compression & Bore/Stroke by year

Engine Size Conversion Table
Converting engine displacement from CID, Liters, C.C.

Engine Overheating Basics - 16 Common Causes of an Overheated Engine

Fan Clutch Diagnosis
How to tell if the Fan Clutch in your Cooling System is failing or has failed.

Automotive Gauges & Instrument Functions
Information they display & their importance.


From the
Department of Cheap   Tricks and Useful Tips

Ultra-Cool Hand Throttle for Free!

Jeep V8 Swap Tips

The Exploding Clutch

Radiator Protection using 6 bucks worth of material

Cracked Under Pressure - Fixing a smashed fingernail

A Cheap, effective alternative to undercoating

Home-built Saginaw Gearbox Brace for the cost of lunch!

Ammo Box Storage - Mounting Them for Quick Disconnect

Home-built Serious Skid-Plate protection for the Oil Pan for under 20 bucks!

Ramp Travel Index
RTI / Ramp Travel Index  What it is and how to calculate it, with and without the ramp.





Project Jeep CJ-7   

Back to Project Index

Fabricating an Exhaust System


I had several reasons for deciding to fabricate my own exhaust system.  For one I already had several pieces to the exhaust system like a pair of after market mufflers and one, new short catalytic converted that all came from Mike at www.Jeepfan.com in a package deal.  Second reason was that fact that, again, I have more time than money and I need to get my money out of that welder I bought.  (08/12/2001)

The following is pretty much a recap of fabricating the exhaust system along with a few good tips and things to considering with the V8 360.

First thing I had to acquire was a different exhaust manifold on the driver side.  The stock 360's manifold came right down on top of the clutch linkage.  An exhaust manifold from an AMC 304 exits further forward as pictured below and thus clears the clutch linkage.

A trip to the local exhaust shop yielded a pair of seals and flanges. The flanges were then welded to a short piece of 2 1/2" stock exhaust pipe.  The rest of the exhaust system was a series of 45º angles, 90º angles and straight lengths of stock pipe all bought from a local auto parts dealer for a few bucks.

I used a few pieces of wood that bridged across the top of the frame and I hung the mufflers and cat converters already pressed together.  From there I measured from the exhaust manifolds to the cats on either side.  Driver side had to take a drop down below the clutch linkage and back up.

Each piece was welded to the next except for a few places where it would be c-clamped to make it easier to take it apart if necessary. I used a low power setting on the welder to prevent burning holes though the thin walled exhaust pipes. 

Below you can see where I snaked the exhaust out the sides behind the wheels.  Here's  tip, don't run them out of the rear of the vehicle, Jeeps in particular, or you'll be breathing exhaust every time you ride with the top down.  Sending it out the sides and it will catch the wind, not ride up the rear of the vehicle into the air you breath.

Above and below, routing around the rear axle.  The pipes exiting behind the rear wheels were later bent further rearward more like a 45 degree angle rather then straight out the side.  That was to clear the Super Swampers at full compression of the rear suspension.


The image above show how the dual exhaust was routed.    Notice how one catalytic converter is further forward than the other.  One was shorter and I was able to take advantage of the space above the skid plate which also put the muffler in a good spot to use the hanger already on the frame.

Directly below shows a good example of a very slight bend in the exhaust pipe.  A good tip to make such a slight bend is to cut though the pipe with an angle grinder and a thin cutting blade all the way around the inside side of the bend but leave about an inch of pipe on the outside of the bend of the pipe.  I cut about a 3/4 inch notch out of the inside side of the bend and then closed the gap thus making the slight bend.  Then I re-welded it back together.  There were several instances of doing this to tweak the angles.  Angles are the name of the game when it comes to exhausts.  Hangers were bought and hung from several locations to support the system. 

Click above picture for a close up

Click above picture for a close up

Heat Shields

Later, after the new brake lines were installed several areas needed to be protected from heat from the exhaust.  One area was at the passengers side below the exhaust manifold and the other was the passenger side where fuel line ran above the skid plate in the area of the catalytic converter.  Sheets of bend and manipulated aluminum were used to shield from the exhaust system's heat.

One other place an aluminum heat shield was used was above both mufflers.  This was done later after it was discovered that creeping slow on the trail allowed a lot of heat to build up under the floor of the Jeep.  Enough heat to melt a plastic bag that was laying on the floor of the Jeep.  It also melted some of the contents of the bag, in particular the chocolate in my homemade trail mix.  The fix for the heat transfer from the dual Flowmaster mufflers was a large sheet of thin aluminum coil, the kind used for capping exterior woodwork on homes.  You can get rolls of this stuff from home supply stores like Home Depot of Lowes.  I used a sheet about 3 feet wide by 2 feet and bolted it under the floor between the frame rails and above the mufflers.  That stopped just about all of the heat transfer through to the floor.

Above, Heat shield to protect the gas line.

3 pics below, heat shield to protect the brake lines and proportioning valve.


Project CJ-7

Fabricating an Exhaust System

Back to Project Index




Offroad Tire Info
Tire Terminology
Wheel Terminology
How to Pick the Right
Tires for your Truck
Truck Tire Info
Tires - What Hits What Fits
All Terrain  Mud Terrain
Tire Reviews & Info
Mud Terrain MT Tire Reviews
All Terrain AT Tire Reviews
Super Swamper Bogger
Super Swamper SSR
Super Swamper SX
Super Swamper Vortrac
Interco IROK TSL
Super Swamper LTB
Super Swamper TSL
Super Swamper TSL Radial
Super Swamper Narrow
Interco SS-M16 Swamper
Thornbird TSl Radial
Thornbird TSl Bias
Thornbird TSL
Parnelli Jone Dirt Grip
BFGoodrich Krawler
BFGoodrich MT T/A KM
BFGoodrich MT T/A KM2
BFGoodrich AT TA KO
BFGoodrich Mud King XT
Bridgestone Dueler MT
Cooper Discoverer ST
Cooper Discoverer STT
Cooper Discoverer ST/C
Firestone Destination MT
General Grabber MT
General Grabber AT2
Green Diamond Icelander
Ground Hawg Mud Tire
Hankook Dynapro MT
Hankook Dynamic MT RT01
Hercules Terra Trac MT
Hercules Trail Digger MT
Kelly-Springfield Safari DTR
Kelly-Springfield Safari MSR
Kumho Road Venture MT
Kumho Road Venture KL71
Kumho Road Venture AT
Dick Cepek Mud Country
Dick Cepek F-C II
Dick Cepek Fun Country II
Dick Cepek Fun Country Nylon
Dick Cepek Fun Country Kevlar
Mastercraft Courser MT
Mastercraft Courser HTR
Mastercraft Courser HTR Plus
Maxxis BigHorn Radial
Maxxis Creepy Crawler
Maxxis Trepador
Maxxis Buckshot Mudder
Maxxis MA-SW
Maxxis M-8080 Mudzilla
Maxxis MT-754 Buckshot
Maxxis MT-753 Bravo
Maxxis MA-751 Bravo
Maxxis MA-S2 Marauder II
Maxxis MA-S1 Marauder
Maxxis MT-762 BigHorn
Nitto Mud Grappler
Nitto Dune Grappler
Nokian Vatiiva MT
Pit Bull Rocker Extreme
Pit Bull Maddog
Pit Bull Growler
Goodyear Wrangler MT/R
Pro Comp Xterrain
Pro Comp All Terrain
Pro Comp Mud Terrain
Pro Comp Xtreme AT
Pro Comp Xtreme MT
Toyo Open Country MT
TrXus Mud Terrain
TrXus STS All Terrain
Mickey Thompson MTZ
Mickey Thompson MTX
Mickey Thompson Baja Claw
Mickey Thompson Baja Crusher
Competition Claw
Dunlop Mud Rover
Yokohama Geolandar

Latest trips Offroad
... trail reports with the Project CJ-7
click here.

Sounds System, Raised the Rear Seat
Storage below and a great place to mount 6x9 Speakers for Great Bass ... In a Jeep!

York AC Compressor Conversion.  What used to pump Freon, now pumps compressed air to the front and rear bumpers.  125 psi,  2 gallons of storage, air fittings at the bumpers, enough CFM to power air tools!.  Click Here for more  Details


Dick Cepek's 2008 F-250 Super Duty Project Vehicle ? Project CRUSHER

Warn X8000i
Winch Installation

ARB Air Locker Install
Jeep Wide Track Axles Swap

Mud Tire Reviews

Building a Garage?
Need a Garage Plan?

Reader's Rigs and Seriously Stucks!


Jeep Trans Swap Info
T-18A Transmission Rebuild & Short Shaft Conversion