97 80 series aftermarket exhaust questions.

[JWR1991]

Good evening everyone!

I just purchased a 97 FJZ80 and it’s in need of some restorative work. My highest priority is the massive exhaust leaks. After work, I got under the truck to find both cats, the Y pipe, and the muffler all have holes, which leads me to want to replace the entire exhaust, from the engine back. I’ve seen some options that are decently reasonable, but everything I’ve seen lacks catalytic converters. I’d like to retain O2 sensors with cats, and preferably a very mild exhaust tone. I don’t know that I want to piece together a stock exhaust with used parts. What I am currently thinking is, purchase one of these engine back exhausts, a 2.5” cat, and some weld in o2 bungs but I am open, and looking for other options.

Thanks!

 

[OffRoadScott]

Look into the 105 series header. It is routed inside the frame vice outside like yours runs now. You can source universal cats from Amazon or pay once cry once and get Magnaflow cats have a muffler shop do the custom work as far as weld in the cats or have flanges welded so you can bolt the cats on. There are different options available as far as mufflers, depends on the tone and space you are working with.

 

[JWR1991]

Look into the 105 series header. It is routed inside the frame vice outside like yours runs now. You can source universal cats from Amazon or pay once cry once and get Magnaflow cats have a muffler shop do the custom work as far as weld in the cats or have flanges welded so you can bolt the cats on. There are different options available as far as mufflers, depends on the tone and space you are working with.

Thanks for the quick reply Scott. Inside the frame seems way safer than their current location. It looks like they may be the lowest part on the undercarriage. I’ll look at the 105 series headers. Even the Manta Brand exhausts look like they route outside the frame.

 

[COS80]

I have custom 3" exhaust on my 97, manifold back. The PO did it, and had it redone, from the cat back, after mangling it off road. In CO, exhaust work is a freakin' fortune... almost $900! If it's anything like this in MD, you might want to focus on off-the shelf systems, but I don't know what's out there.

 

[BILT4ME]

Check and read the entire thread here:

Bosal , your $200 cat-back option

I wanted to put this here for anybody thinking of re-doing there exhaust. When I started this project my exhaust was bad, really bad. It was leaking at the seal between the rear cat and the cat-back. Only one of the exhaust hangers had not rusted off and it was being held by some pipe strap...

forum.ih8mud.com

I am also going to find where I posted more info and I will copy it back into this post.

'96 Borla or Bosal Cat back?

forum.ih8mud.com

 

[Fj80oregon]

If you try searching, many have used the maganflow ypipe including me with great success. Then have an exhaust shop child the rest.

 

[06reg4x4]

Depending where you are in Maryland there are some good options there. Tony’s constom exhaust is Glen Burnie being one.

 

[jonheld]

I have the Magnaflow downpipes/single cat and Bosal replacement muffler. Had a local hot rod shop fab up a custom over the frame exhaust out of T304 stainless using all OEM hardware/hangers/O2 sensors.
Had the Magnaflow ceramic coated before installation.

 

[JWR1991]

Check and read the entire thread here:

Bosal , your $200 cat-back option

I wanted to put this here for anybody thinking of re-doing there exhaust. When I started this project my exhaust was bad, really bad. It was leaking at the seal between the rear cat and the cat-back. Only one of the exhaust hangers had not rusted off and it was being held by some pipe strap...

forum.ih8mud.com

I am also going to find where I posted more info and I will copy it back into this post.

'96 Borla or Bosal Cat back?

forum.ih8mud.com

This was extremely insightful, thank you far sharing!

 

[JWR1991]

Depending where you are in Maryland there are some good options there. Tony’s constom exhaust is Glen Burnie being one.

I'm up in Frederick. I am not opposed to driving to Glen Burnie for the right outcome.
Did Tony's do your 80 series? If so were you happy with the result? and were you happy with the price? The thing I am considering/concerned with is the condition of the hangers when I start messing with them, and them being an exhaust shop, it's nothing for them to fab up new hangers. Also if bolts/studs/nuts are seized up I don't have to mess with them but ultimately will end up paying for it.

 

[06reg4x4]

I’m no longer in Md but Tony’s has always been a go to shop for that. They did my b13 se-r and some other projects.

 

[06reg4x4]

And mbs in Pasadena.

 

[mudgudgeon]

The thing I am considering/concerned with is the condition of the hangers when I start messing with them

Replace the rubber blocks.

Pic is generic from eBay, but this is what you're looking at.


They are a few dollars each from toyota.

The stud is part of it, and nuts come with them.
The brackets on the frame are heavy steel, and shouldn't need to be touched unless your are customising something.

 

[smritte]

All the good exhaust shops near me are gone. I just did the Magnaflow down pipe and Borla stainless. Fit and sound are great with the only down side being it goes straight out the back. I prefer it to come out just behind the tire. Cutting and twisting the end looks like it will be easy.

 

[alia176]

I redid the entire exhaust after the turbo went in. Sound and flow is rather subjective but I still had to go with a tailpipe resonator to cut out the drone. I do suggest using V band clamps at all the junctions for future ease of removal. This will drive the price up quite a bit but no more leaks or gaskets, and things fit up easily. Your local speed shop will have them but Kartek has a decent price shipped to your door.

Before the turbo, I had a Bosal with a different branded tailpipe resonator and it was decent sound. Bosal's tailpipe resonator was silly!

 

[reklund5]

I've got a BRExhaust (magnaflow) cat-back sitting here for a friends 80. Cursory look in the box shows it looks decent, but its definitely a budget setup. I'll try to get some photos during install.

 

[JWR1991]

Replace the rubber blocks.
View attachment 3822670
Pic is generic from eBay, but this is what you're looking at.


They are a few dollars each from toyota.

The stud is part of it, and nuts come with them.
The brackets on the frame are heavy steel, and shouldn't need to be touched unless your are customising something.

Excellent. That’s reassuring.

 

[JWR1991]

I’m no longer in Md but Tony’s has always been a go to shop for that. They did my b13 se-r and some other projects.

I’ll definitely look up Tony’s then. Would you recommend I provide a Y pipe and muffler to them and let them fab up the rest?

 

[06reg4x4]

Yup. Get the 105 part.

 

[JWR1991]

Yup. Get the 105 part.

Would a 105 aftermarket exhaust fit an 80 series, like the one from Manta?

Pic for example