HJ 61 Exhaust Advice Needed

[Sooke]

Spudman, Nice work on getting all of your pieces ordered up for less than $300, that is great. I would have been able to get the pieces but it was the welding process that held me back. these muffler shops want $100/hr to do anything that isn't straight off the shelf install. Robbery!! As for the aluminized tubing, it isn't entirely aluminum, it must be some sort of coating or something for corrosion resistance. for a 8" length of 3" stainless flex pipe I had one quote of $200 for that piece alone. Ridiculous. I found them on Ebay for less than $30 shipped. At least the one shop is allowing me to bring in some of my own parts and they are going to do the welding and install for around $300. It won't be a stainless system, but by the time I need a new exhaust, my welding skills should be up to par.

 

[muddytrux]

Hi guys just to chime in with my 2 cents.
I used the stock downpipe to the factory ( I think factory ) flexpipe, then a 2.5 to 3 inch reducer to 3 inch straight pipe back, under the floor to the first spring perch then dumped in front of the rear tire. No muffler or resonator. It does not drone, sounds great echoing off parked cars whilst setting off alarms and was built for about $100CDN.
A j-pipe from a speed shop was 60, then a length of 3 inch straight about 30 the rest reducer and clamps. I did my own welding. The j-pipe is great for the selection of possible bends you can do. If possible borrow or rent a porta-band to cut, tack if possible, mark witness lines with a sharpie if not, then bring to a welding shop if you need to.
The nice thing about this exhaust ( other than not droning ) is that you can pull it off easy enough when you pull the tranny to replace the clutch. I will send pictures when I get home but the job is compact and clean. Only part that sucks is pipe under frame could be crushed unless you build a guard...
Oh ya it is not stainless just aluminized steel, sprayed with aluminum coat after then the back half wrapped in header wrap to guard from gravel spray.

 

[Sooke]

muddytrux,
Sounds very similar to what I am about to have installed. Unfortunately my welding skills are non existent at this time so I have to pay someone to do it for me. Only difference is I will have the exhaust exit behind rear tire. Interesting idea with the header wrap to guard from gravel spray. Looking forward to seeing the pictures!!

 

[muddytrux]

Will send pics when I get back from Mexico to get away from this...freezing to the side of the world !

...via IH8MUD app

 

[Spudman]

Hi guys just to chime in with my 2 cents.
I used the stock downpipe to the factory ( I think factory ) flexpipe, then a 2.5 to 3 inch reducer to 3 inch straight pipe back, under the floor to the first spring perch then dumped in front of the rear tire. No muffler or resonator. It does not drone, sounds great echoing off parked cars whilst setting off alarms and was built for about $100CDN.
A j-pipe from a speed shop was 60, then a length of 3 inch straight about 30 the rest reducer and clamps. I did my own welding. The j-pipe is great for the selection of possible bends you can do. If possible borrow or rent a porta-band to cut, tack if possible, mark witness lines with a sharpie if not, then bring to a welding shop if you need to.
The nice thing about this exhaust ( other than not droning ) is that you can pull it off easy enough when you pull the tranny to replace the clutch. I will send pictures when I get home but the job is compact and clean. Only part that sucks is pipe under frame could be crushed unless you build a guard...
Oh ya it is not stainless just aluminized steel, sprayed with aluminum coat after then the back half wrapped in header wrap to guard from gravel spray.

Hey mate, yep I will be doing similar, I'm leaving the original pipe on where it bolts to the turbo and will fit the 3 inch pipe to that, as mentioned earlier on here and then a straight thru over the rear axle and out the back.

The only reason I am going out the back as this method is supposed to stop the drone, but you have proved that theory wrong, so I might consider that option as well.

As for my welding skills it was part of my trade some 30 odd years ago and I've always kept a welder handy so I can keep my skills up.

I also have access to a hoist here, so that will also help heaps

Spudman

 

[muddytrux]

Sooke,

What about this ?

http://www.amazon.ca/dp/B000QJMYGS/?tag=i0bc2-20

Free shipping dude and if you cant build at least 4 systems out of this mess you have to rethink your systems ! Stacks,duels, remove the turbo and have 6 zoomies out the hood !
And this is a 3 inch kit so split it and and sell half....then go to the princess and get a small inverter DC welder with tig kit !

 

[Sooke]

Holy frozen land!

You deserve a trip to mexico my friend, old man winter still has his cold fingers wrapped firmly around your neck.....geez

So, I went out and bought a gasless mig welder and an exhaust pipe expansion kit from princess auto. I am going to build it myself. I'll practice on a bunch of pipe until my welds are decent. With the pipe expander all of my joints will be lap joints so it will be easier to tack, measure, adjust, re-tack etc

Only one way to learn and that is to just jump right in... Have a great trip!! We recently retuned from a week in Puerto Vallarta.

Great looking truck. I'll round up a few pics myself.

Cheers,
Cody

Will send pics when I get back from Mexico to get away from this...freezing to the side of the world !

...via IH8MUD app

 

[Sooke]

That is a good price for all of that stuff, like you said, you would have enough for two complete systems... and free shipping, that just might be the way to go. Going to check how much my local auto parts store will charge for the pieces I will need and then decide from there. I'll move up to a TIG when my skills get better..

Sooke,

What about this ?

http://www.amazon.ca/dp/B000QJMYGS/?tag=i0bc2-20

Free shipping dude and if you cant build at least 4 systems out of this mess you have to rethink your systems ! Stacks,duels, remove the turbo and have 6 zoomies out the hood !
And this is a 3 inch kit so split it and and sell half....then go to the princess and get a small inverter DC welder with tig kit !

 

[Spudman]

Sooke,

What about this ?

http://www.amazon.ca/dp/B000QJMYGS/?tag=i0bc2-20

Free shipping dude and if you cant build at least 4 systems out of this mess you have to rethink your systems ! Stacks,duels, remove the turbo and have 6 zoomies out the hood !
And this is a 3 inch kit so split it and and sell half....then go to the princess and get a small inverter DC welder with tig kit !

Muddy that's an excellent price, good find. Definitely the way to go if you're in America.

 

[muddytrux]

Hey Spudman,

Yes in Canada we get Amazon stuff at a decent price but you have access to 12ht parts ! Hoping I get home before dollar collapses and I cant afford all my stuff from Engine Australia...

 

[Spudman]

So my exhaust turned up yesterday, the flex pipe is actually stainless steel, so that will never rust, also I'll have to use clamps to hold that on, not good on welding stainless steel

Just gotta bug my mate enough so I can use his hoist, hopefully Sunday

 

[Sooke]

Best of luck to you mate,
I got motivated to try and do it myself as well after getting some ridiculous quotes. I ordered up a stainless flex section as well, planned on putting stainless lap joint band clamps on each end, good thing about having a clamp in the front is that you will be able to remove the exhaust easier if you need to drop the tranny for any reason. Muddytrux had made that point and I thought it was a great one. I bought a cheap exhaust pipe expander kit so I can make all the joints slip one inside the other (lap joint). I figured it would be easier to make it all fit together nicely. I'll get it all in place with the lap joints and then when I am happy I will tack weld it together and then drop it out and finish welding the final product. It all sounds good in theory!!

 

[muddytrux]

Here are a few pics of my exhaust . Looks like I should pull it off and clean up the bit of rust on the weld and maybe rotate it up a bit. 20k km on it and drone is not an issue.

 

[Spudman]

That's an excellent idea about the pipe expander, wish I'd thought about that one earlier Ah well looks like I'll just have to practice my seam welds

 

[Sooke]

muddytrux, thanks for sharing your pics. I'll make sure to document my attempt. I won't have all my parts until after Easter, so I will have to wait to get started. Until then I am working on fitting a new style ARB bumper onto my HJ61 with the factory PTO winch. There is a well documented fitment by a forum member that I will be referencing. Thank goodness for this site and it's great membership that shares it's collective wisdom and experience.

The pipe expander wasn't too expensive, cost me $130 for the kit. I figured it would save me some grief during the fitment process and it my welds are sub par I could always use decent band clamps.

 

[Spudman]

Have you got a link to this exhaust expander, all the ones I've read about are only good for straightening pipe, none of them actually say they increase the exhaust width to fit over another piece of exhaust.

Thanks

 

[Spudman]

I actually looked further into these and watched a couple of videos on U tube and ended up purchasing this one.

http://www.ebay.com.au/itm/221347383789?

Hopefully it's strong enough to expand, I'll just apply some heat before I expand and it should be quite easy.

spudman

 

[slowandsteady BJ]

Cody

Good on ya for trying to get it done yourself man. If you get hung up, give me a call and I can help you out.

 

[Sooke]

Cam,
Thanks buddy. I won't get all the parts until my folks come for Easter. I order stuff from the states and they go across the border and pick it up for me since they live right on the border in the southern interior of BC. I appreciate the offer to help. I'll see how it goes and give you a ring if I need an expert set of hands..

 

[Sooke]

Spudman,
That looks pretty much like the exact same kit I bought just a hundred bucks cheaper!!! Nice work. Sorry I didn't see your msg earlier. I bought the kit from a local automotive/surplus shop. I think it will help us greatly when fitting it all together. Good idea on putting some heat on it, should make it easier to expand. The pipe I ordered is 14 gauge so it is a bit thicker than the 16 gauge commonly found in the local muffler shops. I think the original Toyota pipe is 14 gauge.