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Discussion Starter #1
I need to map out what I need to buy for my current build. It will be a 4.2L n/a with the m5r2. I will be using the 96-97 tubular manifolds. EGR and converters have been deleted in the tune.

Things that I already own and would like to use if possible:
  • dual 2" tubing from a 98 Mark VIII LSC (trans-back)
  • pair of 2007 Mustang GT mufflers (manual - p/n 7849)
The LSC pipes are 2" OD and the mufflers are 2.25" OD. I know that the V6 tends to be raspy and a resonator is recommended. Would a simple x or h-pipe be sufficient at killing the rasp/drone, or should I look at something else? Will 2" duals be enough, or should I go with the Mandrel Exhaust 2.25" kit? I'm going to contact them about the catless downtubes they made for S4gunn and see if they can be modified for the later manifolds. Does anyone have experience with the V6 exhaust systems? Tips/advice?
 

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I would go with 2", and have an H-pipe welded in for increased low end torque.

Al
 

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I don't know about the drone part but raspiness will be cut by a multi-chambered muffler. Considering that the inlet/outlet pipes on the Mustang GT muffler are not inline, I'll bet dollars to donuts that's what you have. Also, see the pics here.

Manual vs Auto stock exhaust differences - The Mustang Source - Ford Mustang Forums

I can't imagine you will find 2" pipes to be the restriction in your system.


Q: What's the difference between early/later manifolds in relation to downpipes? IIRC, All 3.8/4.2/5.0 exhausts dump out in the same position (where the downpipes mate up).

Do yourself a favor and weld up flanges so you can take this exhaust on/off easily.
I got a 1pc exhaust system with 2" pipes (or 2.5", I forget) that were 1pc from the manifolds down tot he exhaust tips and it was a giant pain in the ass to install/remove. Hated it and was shocked when someone bought it off of me.

It's so much easier to have it unbolt in multiple sections 1) manifolds to X/Y/H pipe 2) each section going back with the mufflers.
 

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Discussion Starter #4
I don't know about the drone part but raspiness will be cut by a multi-chambered muffler. Considering that the inlet/outlet pipes on the Mustang GT muffler are not inline, I'll bet dollars to donuts that's what you have. Also, see the pics here.

Manual vs Auto stock exhaust differences - The Mustang Source - Ford Mustang Forums

I can't imagine you will find 2" pipes to be the restriction in your system.


Q: What's the difference between early/later manifolds in relation to downpipes? IIRC, All 3.8/4.2/5.0 exhausts dump out in the same position (where the downpipes mate up).

Do yourself a favor and weld up flanges so you can take this exhaust on/off easily.
I got a 1pc exhaust system with 2" pipes (or 2.5", I forget) that were 1pc from the manifolds down tot he exhaust tips and it was a giant pain in the ass to install/remove. Hated it and was shocked when someone bought it off of me.

It's so much easier to have it unbolt in multiple sections 1) manifolds to X/Y/H pipe 2) each section going back with the mufflers.
I know that the 96/7 passenger side downpipe has a different angle from the 94/5 because I had to have it modified way back when I first put a 97 engine in my 94. I'll get a picture of the stock setup I pulled from my 96.

I do plan to have it sectioned for easy removal. Would an h or x-pipe benefit me at all, and if so which would be better? I picked up the pipes a while back on a whim for like $10-15 at the yard, and the mufflers on CL for like $15 so if I can use them that's awesome. My previous setup was 2.25" single (no cats) with a y behind the pumpkin to 2x 40 series Flowmasters. Sounds awesome at idle, but nasty rasp at 3k+ and horrible highway drone.

Pardon my newbish questions. I've never researched exhaust systems much before.
 

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I know that the 96/7 passenger side downpipe has a different angle from the 94/5 because I had to have it modified way back when I first put a 97 engine in my 94. I'll get a picture of the stock setup I pulled from my 96.

I do plan to have it sectioned for easy removal. Would an h or x-pipe benefit me at all, and if so which would be better? I picked up the pipes a while back on a whim for like $10-15 at the yard, and the mufflers on CL for like $15 so if I can use them that's awesome. My previous setup was 2.25" single (no cats) with a y behind the pumpkin to 2x 40 series Flowmasters. Sounds awesome at idle, but nasty rasp at 3k+ and horrible highway drone.

Pardon my newbish questions. I've never researched exhaust systems much before.
Interesting video

These people seem to believe that the XPIPE will cause raspiness and the Hpipe is the better choice
http://www.allfordmustangs.com/forums/2011-2014-v6-mustang-tech/323139-h-x-pipe-one-better.html
 

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Discussion Starter #6
From that video it doesn't looks like either one does much at all at high speed.
 

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From the video it looks to me like the x pipe equalizes pressure in the pipes at high flow and the H pipe does this at low flow. With my xpipe in my 5.0 I at WOT I was past the redline for rpm when the AOD would shift. That and the drone/loudness caused me to use the dual in/out resonator instead and I added high flow cats. I don't know v6 motors so about all I can say is the xpipe was louder with no cats.


I read the 4.6 handles over 1000 more rpm and it might not be past the redline before shifting. The 4.6 guys generally have the ability to control shifts electronically too.
 

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Discussion Starter #9
I found the Magnaflow 11385 that is 2.25" di/do with an internal x-pipe. I think that is what I will go with. They also make one without the internal x-pipe (11378). This LSC piping is only 2" and I don't see any 2" resonators. Will that be an issue? Also, the resonator and mufflers are stainless where the pipes surely are not. Joe, what mandrel bend kit did you use, and what resonator?
 

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I went with the 2.25 inch system with the 2.25 resonator, bought that from SCP. It has the internal X pipe.

Joe
 

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Discussion Starter #11
I got my Magnaflow resonator in yesterday. I also found a set of 2.25" or 2.5" (I didn't have a way to measure at the time) dual pipes at the junkyard (with the same GT mufflers I'm going to use). Would it be worth the effort and money to swap up to the larger pipes from the 2" I already have? I have contacted MES about the downpipes again. I'll give them a call next week if I don't hear back.

This is the stock 96 3.8 exhaust versus the earlier version. It looks like both sides are different at the manifolds.

1996:


S4gunn's earlier setup:
 

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I'm not sure what you are comparing but from my experience:
93 Tbird 5.0 exhaust manifolds and 95 Tbird 3.8L exhaust manifolds dump in the same position.

The driver's side dumps "straight down" from the manifold and the passenger side dumps at an angle (angled rearwards)

I recently pulled off my exhaust manifolds (93 Tbird V8) and wrapped them to try and prevent my hot starter issue. You can see the difference in angle in the attached pic.

In your pic, it kind of looks like the driver's side downpipe comes down at an angle but it could also be a perspective issue. I think you'd be able to obviously tell yourself by looking at the car.

-g
 

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Discussion Starter #13
I'm not sure what you are comparing...

In your pic, it kind of looks like the driver's side downpipe comes down at an angle but it could also be a perspective issue. I think you'd be able to obviously tell yourself by looking at the car.

-g
That is exactly what I'm comparing ^^. Both sides are different.

MES replied and said they can make your tubes, but any modification would need to be done by me. If that is the case, then I'm better off getting them bent locally because they just plain won't work. How did you get them the correct angles and such when you had yours made? I'm hoping I can talk them into changing the first 2 bends so I don't have to look for a competent shop in town.
 

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That is exactly what I'm comparing ^^. Both sides are different.

MES replied and said they can make your tubes, but any modification would need to be done by me. If that is the case, then I'm better off getting them bent locally because they just plain won't work. How did you get them the correct angles and such when you had yours made? I'm hoping I can talk them into changing the first 2 bends so I don't have to look for a competent shop in town.
1) MES just made the bends based on what they already knew. I told them that I had used a 95 v6 exhaust (stock), a one piece true dual exhaust from a 95 SC I got in trade from Dan, and I had the stock 93 v8 exhaust and all three setups works for me. One of these must have aligned with the template car they did before (SC probably) and that was enough data for them. I also remember maybe giving him some estimates based on my own measurements (my original measurements were for a 90degree elbow on the driver side and a 45 degree bend on the passengerside -- what I got back was more complicated on the passengerside but just as easy).

2) If you take a look at the exhaust he made me, there's a good deal of wiggle adjustability in the front exhaust from the downpipes to the section that goes into the Y (it's in two pieces). I don't know if that's enough variability to give you room but we are basically talking about adjusting the angle of one bend (the driver's side).

A local shop one offered to bend a pipe for me in whatever shape I wanted provided I provided them with a template - they suggested a piece of clotheshanger that I bent while underneath the car to estimate the angle.

I suspect you could do the same but instead of showing the guy the template, you measure the angle yourself and email that data over to Josh.
 

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I'm not sure what you are comparing but from my experience:
93 Tbird 5.0 exhaust manifolds and 95 Tbird 3.8L exhaust manifolds dump in the same position.

The driver's side dumps "straight down" from the manifold and the passenger side dumps at an angle (angled rearwards)

I recently pulled off my exhaust manifolds (93 Tbird V8) and wrapped them to try and prevent my hot starter issue. You can see the difference in angle in the attached pic.

In your pic, it kind of looks like the driver's side downpipe comes down at an angle but it could also be a perspective issue. I think you'd be able to obviously tell yourself by looking at the car.

-g
Now that's what my 4.2 exhaust looked like.
 
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