Event Reports
4x4 Riverland Challenge 2009
4x4 Mud Dust & Music 09
4x4 Riverland Challenge 08
Victoria 4WD Trip June 09

New Articles
AWD and Odd Sized Tyres
Outback Low Range Conversion
Windscreen, Spray then Wipe
Storage and Sleeping System

Project83
Intro - the idea and plan
4WD Conversion
Fender cutting
Radius Rod Mod
CD Player install EA81

Concept Subaru's
Bobbed Subaru Brumby
2005 Subaru Brumby/Brat
2door STi Convertible
Forester Pickup Truck
EA82 hatchback
Other Photochops

Getting the exhaust perfect is a very important part on an offroad Subaru. It needs to be able to tuck up under the body as close as you can get it to avoid damage. The stock Subaru Liberty/Legacy Y-pipe (headers) doesn't fit the EA81 style chassis and gearbox crossmember very well. To get it to fit here's what we had to do: Cut the left pipe in two places. First the front part just after it makes it first turn from the heads. Second the part between the second band and the catalytic converter. Both needed a approximately 10mm cut out. The right side of the Y-pipe also needed a slit in it to allow the pipe to bend around to make up for this gap that was just cut out. Next we bolted it into position and held it while spot welding it back together. You can't weld right the way round a exhaust pipe under a car so you need to tack it in a few places to get the angles right then pull it out and finish the job. This is exactly what we done. We found when we cut the left side of the Y-pipe we took too much out. So we got another length of pipe and cut a slit in it length wise , this then stretched out and slotted over the gap. This was welded in place when we were tacking it together under the car.

The important part here was to get the catalytic converter rear outlet pipe right in the middle of the original exhaust arch in the gearbox crossmember. We then measured and cut my old 2" straight through exhaust pipe and muffler to fit the new Y-pipe. This worked out very well. But you will most likely be starting off with a stock exhaust. You can either get the angles and straight pipe you need plus a muffler and weld it together. Or you can take the car to an exhaust shop. Just be warned, it is very loud when there is no pipe bolted on after the exhaust and you can also get heat build up under the car which may light something on fire if sitting still for too long. Best bet would be get the car on a trailer and tow it to a shop.

Also remember that if there is a leak before the catalytic converter you may experience engine problems as the O2 sensor needs perfect exhaust out of the heads. Otherwise it will give your car a wrong fuel/air mix. I also needed to cut out a small hole in the engine crossmember to clear then O2 sensor.

 

 

 

Contact

Text and pictures on this site Copyright © 2005 Thomas Paine. All rights reserved. All copyrights are retained by original authors. If you wish to use a picture or quote the text off this site to your own site or to a online forum please ask for permission first. If you use anything off this site that may lead to damage of my reputation I will have to take the matter further. So do not piss me off!

DISCLAIMER: Thomas Paine, www.OffroadingSubarus.com, does not warrant or make any representation regarding the use, or results of use of the information contained on and within this website as to its correctness, accuracy, currency or otherwise. Thomas Paine, www.OffroadingSubarus.com, expressly disclaim all liability or responsibility to any person using the information or advice contained on and within this website.