Catalytic converter question
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Elder User
Joined: Mar 2006
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From: Slippery Rock, PA
Catalytic converter question
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
Tuned
Joined: Jul 2007
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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
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Elder User
Joined: Mar 2006
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From: Slippery Rock, PA
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
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Elder User
Joined: Mar 2006
Posts: 605
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From: Slippery Rock, PA
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
Post Fiend
Joined: Jun 2002
Posts: 13,873
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From: Atlanta GA
> 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.
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.
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Elder User
Joined: Mar 2006
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From: Slippery Rock, PA
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
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Elder User
Joined: Mar 2006
Posts: 605
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From: Slippery Rock, PA
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
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