On a recent wheeling trip near Golden, BC, I attempted to cross a bog that was also the tail end of a small rock-slide. Now, I can handle a small rock garden, and I can handle a bog, but when the two were combined, it took it to a whole new level of metal mangling I haven't experienced before.

I now have a very solid idea of where both my driving skill limits, and the limitations of my JK Unlimited X's stock suspension and tires sit. Needless to say, now I have to deal with the fallout, which includes a slightly dented front crossmember, a small crack in the evap canister, and a crunched muffler (see below).



I have a handheld grinder that I believe is sufficient for cutting the exhaust tubing (alternately, a hacksaw would work, no?), and no welding skills (nor does anyone I know). I'm comfortable with holding everything together with clamps and metal hanger strapping for now and perhaps having a muffler shop weld it all up at some point in the future.

As far as the muffler goes, here's the plan:
(I'm trying to stick to a bit of a budget here (saving for an engagement ring ), so cheap is good )

1. Cut the stock muffler off at its entrance and add ~12" of straight 2.5" exhaust tubing to dump the fumes out the back of the Jeep. (Alternately, just un-clamp the muffler, and clamp on a 45-deg bend followed by ~12" of straight tubing)
2. Find a basic muffler that will fit in-line between the spot where the left and right cats join, and the spot where the piping gets all bendy to clear the rear suspension.
3. Cut an appropriate section that is smaller than the muffler (to allow for piping vs. muffler entrance overlap), slot the muffler in-line, and clamp it all down.

Assuming that I select an appropriately sized muffler, this should leave me with an exhaust system that is significantly less likely to be mangled by a rock, yes?

Did I miss anything critical that will screw me over in the long run?

As far as muffler selection goes, I'd like any input you might have. I'm not looking to add power or make it sound "big and mean"; the stock exhaust sounded fine to me. That said, I'm not opposed to a little more grunt, I just don't want it to sound like a beat-up old glasspack...

I've found what I think is a good deal locally on the Cherry Bomb Turbo ($45 CDN from Part Source). Recognizing that one usually get what one pays for, is there something I should know about this muffler?? Everything else that I've compared it to seems to be priced at $100 USD or more...

Thanks for your ideas in advance!

And because everyone loves a little gratuitous carnage, here are some other shots from the underside (although the third one might be an old leak...):

 

So, I've ordered a Flowmaster 40 Delta for $68 CDN, inlet and outlet offset to the same side (the plan is to have the majority of the muffler to the inside of the Jeep). Word on the street is that the Cherry Bomb Turbo is cheap (rolled instead of welded) and not baffled, whereas the Flowmaster is baffled and therefore should sound significantly less barky.

I'll post pics when it arrives and when I get to the metal-cutting bits, and I'll post before and after audio clips as well.

Wish me luck!

 

i would like to hear ur flowmaster after install.

the evap can probly be had cheap on a famous auction site we all know and luv relativly cheap(my spelling sux i know but its late here and i just dont care anymore tonite.)

as for saving for a ring-go cheap- the divorce generally runs 10 to 20 times the cost of the ring assuming no kids and if there is a house and car involved-u wont get the house.

good luck

 

I had ran over a broken pallet on the highway a few days ago and had retained some damage to the exhaust and a broken weld on part of the hanger attached to the pipe. I was torn between fixing what was broken and complete replacement.

I went with what was immediately available from a local supplier. I bought the MBRP stainless cat-back. Took a cutting wheel to the OEM exhaust, and in less than two hours had on a nice sounding, nice looking, cat-back system.

The sound is throaty and far from ricey sounding, which was a concern I had. At highway speeds the MBRP is almost masked by the tire noise, so it is really quiet.

 

I installed a Flowmaster 40 where the EVAP canister used to be after relocating the EVAP above the rear axle. MANGLED the hell out of the muffler to the point where it pinned itself against the rear crossmember. Chopped the muffler off and now I'm running muffler-less. Straight-piped and dumped.