My 87 Bronco II the flange between the converter and muffler was cut off at some point before i became the owner and im about to replace the exhaust. what size pipe will fit inside the pipe where the flange should be? i will just weld it on to the cat and then run a tail pipe so i can still take it on and off in one spot. i think the ID is like 2.5 on the cat or maybe 2.25 but thats why i am here to ask u all what size it should be

 

anybody know?

 

on mine it seems to be an odd ball size, probably designed that way so its harder to hook up a regular pipe and bypass it. mine is larger than 2-3/4, but not quite 3". i would recomend going to the wrecking yard and cutting the end piece off of a doner, then welding the stub to your cat and going from there

 

i think i can get a 2.5" pipe inside the cat and weld it maybe throw a piece of sheet metal around it to to make sure it sealed. then run a 2.5" pipe and a thrush turbo muffler

 

was thinking of something like that when i was working on mine, but i dont know how to weld and am too cheap to line the pockets of the muffler shop...

 

well im still in high school and i go to votech for Auto body and collision repair and we have welders there so i will just do it there. from what i hear its not too expensive to have muffler shops do some stuff like that but im not sure

 

> i go to votech for Auto body

Cut some 3/16 plate about 4" square. Match up to exhaust, draw a circle around the pipe. Get a compass, draw a cross hair to center, then hole saw drill a tad smaller so the hole is a bit smaller then the exhaust pipe. Then drill 1/4" holes at each corner. Weld to pipes. You can buy gasket material and cut it to fit. I just buy a tube of muffler mender and run a bead around the pipe and let it set up overnight per the instructions.

1/4" Grade 5 bolts are fine for the exhaust. Just do not overtighten and bend the flanges too much.

When doing this make sure you clear the skidplate.

 

im going to do it my way first beings how its only temporary till summer when i buy headers a high flow cat and run a different exhaust

 

wellllll heres whats going down. the pipes werent going to work out the way i wanted to so i have to take it to a muffler shop and have the guy weld a new flange on the cat and run a custom pipe system. total cost is going to be $200