It is a shame to have to go with 2" tailpipes but 2.5" looks dang near impossible to squeeze between the leaf spring and fuel tank. 2.25" on my 83 was tight enough it was nearly touching the fuel tank. I briefly considered dumping it near the rear end, then remembered the exhaust has to clear the passenger compartment in my state and probably not the greatest idea with the condition of the current weatherstripping.
This was my evening progress so far. Removed parts of the old exhaust, the old hangers, the manifolds, the downpipes and turn downs I had on the manifolds. Then put the driverside header on and started hanging new exhaust pieces. The muffler is hanging slightly in front of where it might end up residing but needed it for a reference to know how long the pipes would need to be trimmed to and the front hanger is temporarily holding it.
When I said before this old van is pretty much rust free, I was also dead serious. Very solid old van.
I picked up the rear KYBs today that had to be ordered last week. Will throw them on tomorrow too. I have a touch more harness clean up and looming to do as well as a final shake down inspection for missing/loose hardware on anything I touched and it is ready for some drives around town.
A tip for DIY guys. When you crank down those lap band clamps, the tubing might as well be welded. Avoid clamping pipe joints with the horshoe clamps I am using as temporary hangers as they always leak and they crush the pipes in a way you can never take them apart again atleast easily. I have some actual tubing hangers that do not need the horseshoe clamps, but the horseshoe clamps and L hangers make heavy exhaust parts much easier to hang by yourself laying on your back under your vehicle. Leave the clamp a little loose and you can snag into the L of the hanger. I use those for mockup then switch to the cheaper tubing hanger setups as everything falls into place and multiple hangers are holding things up. Always support the front of your exhaust from hangers, never the manifolds or headers.
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