With the addition of the Downey headers, it was time to replace my old and dying exhaust system. I wanted something that would compliment the headers, and offer the best performance possible. After talking with a few people who'd already done headers and exhaust on the V6, I decided to go with a 2.5" exhaust line, and an 2.25" tail pipe.

On Nick Krest's recommendation I went to Custom Muffler in Mt. View. Len is the owner, and does most of the work himself. I told him exactly want I wanted, and he delievered exactly what I asked for. I would not hesitate to have him do work for me again.

 Due to the loss of the stock crossover (with the addition of the headers), a new crossover needed to be created. I had Len do a custom crossover for me. The only option availible to get the passenger side exhaust over to the other side was to wrap it right under the driveshaft. Not an ideal solution, but it works. I'll be creating a skid plate in the near future to protect my vulerable exhaust pipe.

Len also came up with the idea of adding flanges between the Downey headers and the new exhaust, rather than using the slip fit connectors supplied with the headers. This makes the exhaust system much more 'leak-proof,' and will make it much easier to remove the exhaust line should the transmission need to be dropped.

This is the kind of work Len does. He is truely an artist when it comes to exhaust. The is the actual cross-over, where the two sides of the exhaust are combined into one 2.5" exhaust line.

 To compliment my new exhaust line, I purchased a Car Sound catilitic converter from Downey. It has flanged 2.5" inlet & outlets. The muffler I purchased from Custom Muffler. On Len's recommendation I went with a Shuttleworth muffler. I'm VERY pleased with the sound, except for some rapping in the muffler before it gets up to normal operating temperature.

 The tail pipe is very short, and exits between the frame and the spring, behind the tire. It is cut short, and does not protrude past the edge of the frame, so there is no chance of the tire hitting it, or bashing it on the trail.