V6 Block Hugger / DIY Exhaust

So I finally found enough free time to get this exhaust project done. Re-routing the steering took a fair amount of time. Had to make up a couple of short brake lines to re-route them at the master cylinder. Subsequent brake bleeding uncovered lurking problems with rear wheel cylinders.

Yesterday I fired it up. Let burn-in and road tested it. In all I'm happy with it. The project objectives of a new worry-free exhaust system with quality headers and muffler with piping tucked in between the frame rails was achieved. The Flowmaster really sounds nice. Performance wise I really can't tell the difference between these block huggers and the fender well headers. If anything maybe some improvement around 2000-2500 RPM. But then again I haven't had it out on the road in a couple of months. The only problem is the VHT high-temp paint started smoking and blistering as soon as the motor started warming up. That really sucks. I'll need to remove all the pipe, strip it and repaint it with a reliable product.


Here's the re-routed steering shaft and added support (rod end).




This is the complete system. Three rubber supports. So far no contact anywhere. We'll wait and see what happens when the frame twists!




The headers are not installed in this picture. This is the heat shield I built for the starter and solenoid. The cables and wires are in corrugated loom and wrapped with reflective tape. This all can be accessed and removed with headers in place.




This is a picture of the starter after installing the headers. Close but workable.




The exhaust comes from the passenger side header going forward, over the front driveshaft and around the oil pan. I was careful to ensure that the oil pan can be removed without interference.




After turning rearward and collecting the driver side header it comes back above the crossmember.




This is the joint just rearward of the crossmember. I put this in to make future removal easy. Which I guess I'll be doing to remove the crappy VHT paint. Notice the nice thick flanges, solid copper gasket and double nutted stainless hardware.




After the muffler it crosses under the frame rail just aft of the bump stop. My bump stops have an 1-1/2" extension so there is just enough room. The pipe goes past the rear tire and 45s at a slight downward slope for good drainage. The tip is tight at the end of the stock rear crossmember.




Here is the front half looking level. It just barely peeks out under the frame.




Getting past the crossmember I was able to get it a little high. as you can see the muffler is well up inside the frame rails.




So all in all I'm happy with it. Well up out of the way. So now I'll make some sliders and figure out a way to protect the frame bracket for the floor pedals. But first a couple of trips to the desert!

 

Nice! I've been waiting to see this come togtther. Everything looks professional, down to the custom heatshield. Good thinking putting those disconnect flanges in--looks like they're already paying off. Also, good to know about the VHT results...did you apply the paint according to their instructions? What will you use next?

 

Exhaust looks great man. Very clean and simple

 

Good job man, looks great

 

69 Willys, paint prep was good. Been using rattle cans for decades. At minimum a light scuff and isopropyl alcohol rinse and multiple light coats. No, the paint simply cooked.

Thanks for the kind words guys.

 

OK thanks, that's good feedback. I'll be staying away from VHT.