seeking advice/insights on exhaust systen fabrication...

[/pine]

I'm looking for some hands on experience for making up an exhaust system for a old CJ5...
...Basically I'm seeking advice on the best way to make a double offset in a section of standard (1-3/4") exhaust piping...

I have a very small window (opening) above a cross member and between the transfer case on one side and PTO shaft on the other...clearances for multiple clamps etc. is extremely minimal...so I need to have a short section of pipe that has a double offset in a very short span...

My first and main question is what is the best way to make these offsets in a piece of pipe...?
Would it be preferred to just heat the pipe and try to make the bends (offsets) without any welding or will I need to make some cuts (gaps) in the pipe make the offset and then weld the (closed up) gaps ?

 

[George2615]

Heating and bending has always resulted in kinking the pipe every time I tried it. I have had good success cutting pipe on an angle and brazing the pipe back together with a torch and coat hangars. It didn't look good but worked.
Your best bet (and probably cheapest and quickest) would probably be to take it to a Cole, Midas, muffler shop and have them make the offset you need on their pipe bender.

 

[/pine]

Heating and bending has always resulted in kinking the pipe every time I tried it. I have had good success cutting pipe on an angle and brazing the pipe back together with a torch and coat hangars. It didn't look good but worked.
Your best bet (and probably cheapest and quickest) would probably be to take it to a Cole, Midas, muffler shop and have them make the offset you need on their pipe bender.

Thanks for the insights...I thought about filling the pipe with sand etc. to prevent kinking... if I was just going to try heating and bending...but I'm afraid this method would make the section of pipe too long?

Would silver solder work with the other option?

 

[CDN Farm Boy]

You can buy ready made, pre bent sections of tubing, usually called 'J' bends or 'U' bends for their obvious shape. Dozens of online auto parts retailers to choose from.

Cut out the sections you need to make the bends you want and weld them together. Other than the welds, its full mandrel bent stuff so nothing to effect exhaust flow.

 

[George2615]

Thanks for the insights...I thought about filling the pipe with sand etc. to prevent kinking... if I was just going to try heating and bending...but I'm afraid this method would make the section of pipe too long?

Would silver solder work with the other option?

I would not use silver solder on an exhaust system. Too soft and low melting temperature.
As CDN mentioned you can get pre bent short pipe pieces at most auto parts stores (45's, 90's) fit them in place an either braze or mig the pipe together.

 

[square1]

Your best bet (and probably cheapest and quickest) would probably be to take it to a Cole, Midas, muffler shop and have them make the offset you need on their pipe bender.

:yes: I'll tackle any mechanical project...but draw the line at exhaust systems

 

[/pine]

Thanks for the insights...

I have been unable to find what I need at any of the local auto parts supply houses...I will do some more searching online...
...The closest shop with a pipe bender is at least a 75 mile round trip...and since the jeep is not currently street legal I would have to be 100% sure whatever I took (mock up or drawing from one) to a shop would work when I got it home...which might be as much work as actually making the pipe section(s) myself...

 

[CNC Dan]

Cut a straight piece at half the angle you want to end up with, and weld together at 180° .

For tight bends, make two smaller bends.

 

[MinnesotaDaveChalmers]

I'm looking for some hands on experience for making up an exhaust system for a old CJ5...
...Basically I'm seeking advice on the best way to make a double offset in a section of standard (1-3/4") exhaust piping...

I have a very small window (opening) above a cross member and between the transfer case on one side and PTO shaft on the other...clearances for multiple clamps etc. is extremely minimal...so I need to have a short section of pipe that has a double offset in a very short span...

My first and main question is what is the best way to make these offsets in a piece of pipe...?
Would it be preferred to just heat the pipe and try to make the bends (offsets) without any welding or will I need to make some cuts (gaps) in the pipe make the offset and then weld the (closed up) gaps ?

Without your own bender, you are limited to buying pre-bent sections and adding your straight pieces as needed.

People do it this way pretty often for custom builds of all kinds - often in stainless.

Just buy bent pieces, cut the parts where it works for you and weld it up.

For the record, I hate exhaust work with a passion....I bring it in to my local muffler shop for anything other than a quick patch-and-weld.

Last thought, anything can be done with pie cuts.
(not my picture)

 

[/pine]

OK...
I spent some time searching online suppliers with no joy...also talked to the closest shop with a bender and they said they could not make the double bends in the span of pipe required...
...So...using a piece of pipe I went to school and am happy with the results of making some angle cuts...heating and bending to close the gap and welding back up...completely mitering the pipe pieces would probably make it easier to get the angles exactly right but the logistics of clamping the pieces together to make 360* welds would be difficult...I'll try to remember to take some pics when I get through the schooling and get the section fabricated before I install it...

Thanks for the insights and suggestions...