Exhaust Systems

[BlackSheep]

Yo!
I am in need of a new exhaust system for my '97 TJ. I already have the AEM Brute air intake kit, but really need to replace the complete system - including a set of headers. What experience have you had with different header manufacturers? What kinds of finishes (coatings) are best? I figure stainless for the pipe.

What about mufflers? I once read a magazine article about a muffler that is so tough, they showed a photo of a jeep parked on one. I forget who makes that muffler though. The article came out a few years ago - maybe 2004. Might have been JP magazine.

I read a little about some aftermarket catalytec converters. Anyone had any experience with the aftermarket cats?

 

[mbryson]

I've had AWESOME luck with a Flowmaster 70 Series on my XJ. It had TONS of scratches and dings from rocks but never had any issues. I've got a Magnaflow on my 'Jeep', but it's out of the way of the rocks pretty good, so I doubt it'll get hit. It's not built as strongly as the Flowmaster, though.

I've not heard of a good header for a 4.0L that doesn't crack. You living out there in the wet won't help, I'd imagine.

 

[1993yj]

I used to run a Gibson on my YJ, and a Flowmaster on my Dodge w/ the Hemi, but I switched them both over to Aero Turbines over the summer. I didn't try driving on them before I installed them, but they were the strongest made mufflers I have ever seen. Way stronger than my previous mufflers. And they gave more of an increase in power than the other two as well. They don't sell entire kits like some of the other companies do, so you either have to have a shop bend the tubing for you ar do it yourself. I would reccomend checking out their website: http://www.aeroexhaust.com. They have some pretty good info on there, plus they sponsor UROC.

As for headers, I am with mbryson. I just continue to weld up the cracks in my stock ones rather than spending the $400 on new ones. Put that money towards the exhaust kit.

And I also run a high flow cat. I got it for about $80 from a buddy who owns a shop, and then welded it in myself. Can't say that I noticed much of a difference though, cause my old one was all blown out.

 

[BlackSheep]

I used to run a Gibson on my YJ, and a Flowmaster on my Dodge w/ the Hemi, but I switched them both over to Aero Turbines over the summer. I didn't try driving on them before I installed them, but they were the strongest made mufflers I have ever seen. Way stronger than my previous mufflers. And they gave more of an increase in power than the other two as well. They don't sell entire kits like some of the other companies do, so you either have to have a shop bend the tubing for you ar do it yourself. I would reccomend checking out their website: http://www.aeroexhaust.com. They have some pretty good info on there, plus they sponsor UROC.

Looks like nice stuff. Not the same as what I saw in the mag though.

As for headers, I am with mbryson. I just continue to weld up the cracks in my stock ones rather than spending the $400 on new ones. Put that money towards the exhaust kit.

Good advice. Appreciate that. Knock on wood, but I don't currently have any cracks in my stock header.

And I also run a high flow cat. I got it for about $80 from a buddy who owns a shop, and then welded it in myself. Can't say that I noticed much of a difference though, cause my old one was all blown out.

That's a pretty good deal. Some of the ones I looked at are in the $200 range (and up). I'm not sure I really need to replace it, but seems like a good idea if I'm replacing everything else. However, if the header is not worth it, maybe I'll just do a cat back, or find a good muffler and have a shop do it. I don't have the technology to do it.

 

[DevinB]

I've got a Banks header on my 4.0 and a Flowmaster 40 series for exhaust, stock cat. The Banks alone gave me noticeable more power, then when I added the Flowmaster it gave me a little more power and a sweet sound. The key to keeping headers from cracking is quality motor mounts. I've got the MORE bombproof mounts, and I've never had a problem with anything. I'm extremely happy with my setup, the only thing I'd change is switching the stock cat for a high flow unit.

Devin

 

[mbryson]

I've got a Banks header on my 4.0 and a Flowmaster 40 series for exhaust, stock cat. The Banks alone gave me noticeable more power, then when I added the Flowmaster it gave me a little more power and a sweet sound. The key to keeping headers from cracking is quality motor mounts. I've got the MORE bombproof mounts, and I've never had a problem with anything. I'm extremely happy with my setup, the only thing I'd change is switching the stock cat for a high flow unit.

Devin

I ran MORE mounts in my XJ (cracked/welded/rewelded/rewelded stocker) and I have a friend that's been through multiple headers (all have cracked) running MORE mounts. I haven't seen any header longevity difference between my wife's stock ZJ (stock mounts--cracked/welded/rewelded) and my old XJ with MORE mounts.

I believe the 6 cyl header is just a difficult design to keep together. There's just too much going on at the collector to keep it together. We've had pretty good luck with ANY header UNTIL you run a Jeep through the water. My hypothetheory is the uber fast cooling of water on a HOT collector (with 6 collection points) is just not a good combination and causes the cracks. The only header I've seen address this is a newer TJ header. It has a 4 port collector and the other two ports are 'flexible'. When my friend put that on his XJ, we thought he was on to something, but he cracked that one also.

 

[Caleb]

Aeroexhaust.com also supports RME

http://www.rockymountainextreme.com/showthread.php?t=29556

I like to try and support those that support RME

 

[74highboy]

we use the Aero Turbines at my work they sound good not sure how strong they are ive put them on f-350's and mustangs make a nice diffrence in sound and power

 

[bobmed]

We've had pretty good luck with ANY header UNTIL you run a Jeep through the water. My hypothetheory is the uber fast cooling of water on a HOT collector (with 6 collection points) is just not a good combination and causes the cracks.

I've got some experince with this.
Its called thermal shock.
Take something real hot and cool it real fast and it can get very exciting

 

[Brett]

Cracked header......that's why Jeep went to the two piece manifold on the later models