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JeepJunky33 · **Posted:** Thu Feb 23, 2012 1:55 pm

So I am looking into my next upgrades and wanted to get some ideas.
I know that I am going to be needing a new exhaust soon (cause the rustys one sucks and keeps rusting through) (I should have seen that one coming)
I was thinking about replacing the headers and cats as well.

If i straight pipe the cat before the muffler (and leave the other 2 "resonators") will I pass inspection?

OR should I jhust get a free flow cat and be done with it?

Thoughts?
Troy I'm sure you have some info on the topic.

tjkj2002 · **Posted:** Thu Feb 23, 2012 2:14 pm

JeepJunky33 wrote:

Troy I'm sure you have some info on the topic.

Depending on what trans and exhaust setup your '03 has headers maybe a tricky install.Besides JBA stopped making them months ago so the only ones left to buy are the ones some warehouse may have in stock.

Now I do not know NY's exact emission laws but I know some places in NY have the exact same laws as CA so any aftermarket cat is a no go.Besides those advertized "high flow" cats are no higher flowing then the OEM cats,major difference is the OEM cats actually work where the aftermarket versions are not held to the strict standard and why they are not 50 state legal.Yeah the OEM cats are very pricey,but at least it's a no hassle bolt in.I wouldn't worry about the cats till you get those nice P0420/P0430 codes.New NTK O2 sensors would be a good idea,not bosch.

Can't condone the straight piping,if you have the 3 cat setup that 3rd cat is not monitored but is a "catch all" which further scrubs the exhaust.I know my KJ is labeled a LEV for CA because of the 3rd cat.And yes I did retain all 3 cats when I did my SFA swap.

JeepJunky33 · **Posted:** Thu Feb 23, 2012 2:47 pm

Very interesting and all extreamly helpful.

Thanks so much man! I have some looking around to do.

Why 3 cats btw?

Jindosjeep · **Posted:** Thu Feb 23, 2012 7:04 pm

Noticed that on the build sheet for my 02,now I know what it means.I thought that only applied to hybrid vehicles?
Thanks for the info.

JeepJunky33 · **Posted:** Fri Feb 24, 2012 2:53 pm

Well,
Just took a look and my exhaust system is all rusted through. The hangers even broke off. Rustys offroad stopped making the exhaust sytem I got years ago so now I am at a loss.

I dont want to go back to stock so Im thinking I may have to buy parts seperatly.
I know I am going to get the magnaflow muffler 5x8x18 but I dont know the correct configurations (any ideas?)

Also,
Where the hell can a get a tail pipe with a rounded tip with 2.5 tubing?

Help me out please.

JeepinJarhead03 · **Posted:** Fri Feb 24, 2012 3:36 pm

In reference to the JBA headers, call JEGS, was ordering something for a guy earlier and asked if they had any laying around and they had JBA shortys in stainless and stainless ceramic but they were tagged as 05+ and I don't remember what the compats were for the JBA shortys

magnaflow, borla, gibson all make rounded tips

http://lmgtfy.com/?q=rounded+tip+2.5%22+tailpipe

as for the muffler, the pipe reduces to 2.25 just before the muffler, with some cutting and welding you can keep it 2.5 if not it just needs a reducer cuff and use a 2.5/2.5 center inlet offset outlet typically works good on the kjs but a center/center low profile muffler will always fit, you'll have more leeway if you're replacing the pipe

JeepJunky33 · **Posted:** Fri Feb 24, 2012 3:42 pm

Thanks man.
I am looking to replace from the cat back.
So I was looking at the magnaflow 5x8x18 #12246 muffler
and then mybe the dynomax tail pipe (because its cheap)

You think the center/center 2.5/2.5 will work then?

JeepJunky33 · **Posted:** Fri Feb 24, 2012 3:42 pm

Thanks man.
I am looking to replace from the cat back.
So I was looking at the magnaflow 5x8x18 #12246 muffler
and then mybe the dynomax tail pipe (because its cheap)

You think the center/center 2.5/2.5 will work then?

JeepinJarhead03 · **Posted:** Fri Feb 24, 2012 4:09 pm

as long as the muffler and tail pipe don't interfere with the driveshaft you won't have a problem - which with that size muffler, even if the offset outlet was turned to the driveshaft side it would still be a easy route - most that use a rear offset do so because it's easier to mate to the stock exhaust since most use a bolt flange on the inlet side, the offset gives the entire muffler a range of motion to find a sweet spot that makes the rear hookup easiest since the stock exhaust is closer to the outboard side of the vehicle than the inlet is but if you're running new pipe it's not going to matter much, a bend is a bend and with that size muffler you can't get it off bad enough to create interference as long as you adhere to the hanger locations

one helluva run-on sentence sorry.. :lol:

JeepJunky33 · **Posted:** Fri Feb 24, 2012 4:22 pm

Best and most informative sentence ever! Thanks man.
Im pricing everything out and then going to bring it to my muffler shop. (dont have a driveway since I moved)
Looking at the dynomax tail pipe and magnaflow muffler should be a nice combo. ($200)

unless I can get a magnaflow kit off ebay for a good deal.

Will keep you posted.
Thanks again.

JeepJunky33 · **Posted:** Sun Feb 26, 2012 3:14 pm

Need some help.
I went to meineke to replace my tail pipe with a custom bent system (cheaper than having them locate one). The problem is that the guy who used the tube bender made some serious bends to the point that it goes from the muffler exit tip (2.5in) to the pipe with a first bend of about 1inch. I can feel the difference and it shows in my mpg. Is it worth it to just cut the exhaust out after the first hanger and let the exhaust under the jeep?

You think this would be a problem? My only concern is water getting into the muffler.

Thoughts?

Keep in mind this wll be a temparary solution untill I can afford a proper aftermarket exhaust (since Rustys stopped making there's)

tjkj2002 · **Posted:** Sun Feb 26, 2012 3:57 pm

You do know that many others make cat-back systems for the KJ?

Dynomax,Gibson,and Borla just to name a few.If the pipes are not mandrel bent don't bother with them and no local chain exhaust shop mandrel bends tubes which restrict flow.

JeepJunky33 · **Posted:** Sun Feb 26, 2012 4:39 pm

I know they all make systems but Rustys was 100 for a full mandrel bent system and 200 for a system with muffler.

All the others are 300 min. Don't have the cash flow right now for that so I am looking for a quick fix that will work.

Once I get the cas I'm going to get a MBRP exhaust system.

Ideally I'd like a manga flow but they are up in the 500 range.

JeepJunky33 · **Posted:** Mon Feb 27, 2012 10:37 am

Just an update.
I went back this morning and had them cut off the tail pipe they created for me.
I have them take 3" tubing and straight pipe it about 5inchs off of the muffler. Connected that to the rubber mount from the exhaust. Looks great sounds amazing, and its a free flow as your gonna get.

This is only temperary untill I can afford a nice aftermarket exhaust. I guess not deep water crossing for a while.

I have to give them credit too. They gave me most of my money back without me even asking.
Stand up guys.

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