The exhaust system I built for the DJ originally was just to get something on the Jeep to prevent myself from going deaf. It was still way to loud and sounded like bung holio.

Above is what I built. Used parts I had left over from previous projects. That muffler is tiny! The exhaust also dumps right before the rear tire. This looked cool but when you had the doors opens you always got exhaust when stopped. The new exhaust needs a larger muffler and a proper over axle exhaust tail pipe.

The exhaust from the manifold all the way back is all 2″ mild steel tubing. New muffler is a Walker SoundFX Universal 17854. It barely fits but it does fit. Could be shorter. For exhaust hangers I really like using Walker part number 36516.

The exhaust bolts to the manifold with the stock setup (3 bolt setup) but I swapped out the hardened steel donut with a 2″ crush gasket. I never could get the hardened steel donut to seal but the crush gasket sealed up first try!

After the muffler there is a slip fitting that the rest of the tailpipe slides into. An exhaust clamp holds the two together.

This is the tailpipe all welded up. The tailpipe was cut from a 180 piece of tubing. You can see the left overs from the cut.

Exhaust installed back in!

Here is what it sounds like. The new muffler sounds much better (no rattle 4 cylinder noises) and fixing the manifold to down pipe connection got rid of the nasty exhaust leak.

And from the driver seat. Sorry for the YT Link for this one.

Calling this a huge success!