Exhaust - Parts

In this I thought I'd cover the parts to be used, then I'll start on the construction of it all.

Starting from the left are the weld in stainless bungs for the evac system since this car isn't getting a PCV valve. Then 4 heavy duty clamps. These clamps are only to secure the pipes to the hangers and not actually crush pipes together. Next are the main exhaust hangers, they are GM style and in my opinion are easier to work with than the Ford ones. On the right of that are the O2 bungs and all the way to the right are the flanges for the system as I do not like using slip joints and crushing with a clamp.

The 2 mufflers and 2 resonators. The muffler is the quietest in the quietflow series from Walker and is still pretty noisy. I struggled with this aspect as I want the cars quiet but didn't want to sacrifice too much flow in doing it.

For the tail pipes I used this kit to save some time, it still doesn't fit perfect and needs some slicing, dicing and welding to fit properly.

These are the pipes to be used for the rest of the exhaust 0.075" aluminized heavy gauge pipe.

I am going to copy the exhaust I did on the '66 LTD, since this galaxie 500 XL is more or less a carbon copy. I wasn't thrilled on the noise level, but the engine has plenty of pep and low end torque.

In another thread I had these comparisons but I'll post them here again.

1966 LTD Exhaust Video

This is a really good comparison of the exhaust I plan to build and glass packs on other wise stock dual exhaust on a Z code 390 on the parts car '68 LTD.

1968 LTD Exhaust Video

Both short videos are from the same camera and no sound alterations. Turn up the bass for the best contrast between the two.

Note: I had 3 propshafts from 352 and smaller engine cars and they use the smaller Cardan joints. I just tossed them as I only wanted the heavy duty parts of the 390 and larger engines came with.

Lots of things I notice on the 3rd gens don't make much sense, but Ford was probably too large to notice savings in different areas by consolidating part types.

FrankenExhaust

With all the hoo-ha going on I finally was able to make a little progress. It's lobster time!

First was to cut a boat load of the same slice. Each slice is so angled and measured in length that 5 pieces assembled yield a 90˚ elbow on a 4" radius.

Creating the X pipe.

Done

Fitting the front half of the system together. Tis a bit tedious. The '65-'66 with its centre hung parking brake cables was never meant to sport an X pipe. The space between the cables and the tail shaft is very small and precision is everything. Interestingly enough the '66 full size with the 352 did have a factory cross over pipe and dual exhaust, but it was a skinny pipe.

There's about 20 sticks of 1/16" TIG rod in this front portion. With 0.070/5" wall it's one stout and heavy piece.

It's not very elegant but it is very functional.

It will be ceramic coated when finished and running to reduce heating of nearby components.

In order to complete the rest of the exhaust I need the body temporarily bolted back on with a fuel tank.

However as a side note, the following pictures were meant as a joke since I was TIG welding my little heart out anyway.

A poor mans weight set. These are left over parts from the axle and fitting the rear disc brakes I was going to toss but made this as a joke more or less.

However there is a more interesting fact in cutting the splines off the shafts to join them into an automotive barbell. These are the 28 spline axle shafts from the heavy duty (large bearing) Ford 9" and my band saw sliced right through them like cheap steel. It was a little alarming at just how soft these old axles are/were.

I made some spare tyre mounts for the trailers and I used the old axle shafts from our 2004 Grand Marquis when it chowdered its rear axles in the 8.8. The band saw wouldn't cut through them, I had to use the chop saw with the metal cut off wheel to get through them and it took forever to do even that.

I'm glad I upgraded the axle shafts in this car, although I didn't in the '66 LTD and now I fear that might be on the list of things to do when it's road worthy.

Continued in the next post.