For Sale 4.0 OHV Exhaust/cat flanges

[Shran]

I am building these as a side project to hopefully make doing your own custom exhaust a little easier - or maybe your catalytic converter was stolen and you are having some sticker shock at the price of a new one... whatever the case is, using an aftermarket catalytic converter is usually substantially cheaper than a full OEM assembly. This part will convert your factory Y pipe into a single 2.5" round outlet without modifying it at all. Simply unbolt your existing catalytic converter, bolt my part on with a new gasket & new bolts, and clamp or weld new pipe after that. Here are a few details you need to know:

• This is NOT a cat delete device; it is a violation of federal law to use it as such. Don't do it.
• Fits 1990-? 4.0 Rangers & Explorers, possibly some late 80's-'92 trucks with 2.9 V6 engines
• Does NOT fit any other application and I do not have a part to fit those at this time.
• Assembly is approximately 8" long w/ 4" of straight 2.5" tubing at the outlet
• Flange is 1/4" mild steel, CNC plasma cut to the shape of your flange
• You will need to cut a section off of the inner Y pipe to accommodate the squeeze into one pipe - see second picture. Leave approximately 1/2" to 1"
• Be sure that this is what you need, there will be no returns.
• Price for a complete conversion piece is $65 plus shipping and the price for the flat flange ONLY, DIY version is $25+ shipping.
• These are made to order; I have 3 complete assemblies and 3 flanges on hand as of 1-21-2024
• Private message me to order.

 

[Josh B]

From here does it use 2.5 inches the rest of the way?

 

[Shran]

From here does it use 2.5 inches the rest of the way?

It could if you want, or you could increase it or decrease. 2.5” was the easiest to neck down into because the oval part of the cat flange is 2.5”.

 

[Shran]

This is basically what you end up with after install (this particular one used the remains of a factory flange.) I built a bunch of them like this to use aftermarket cats when the factory ones were rusted out but it became really hard to find good flanges with usable studs. Y pipes are easy.

 

[bobbywalter]

Amazon.com

maybe have a pic with that....

 

[bobbywalter]

in the past i would smash one side of a 3 or 3.5 pipe to an oval then add a reducer. to minimize weld needed.


the way your doing is much better and stronger.

 

[Josh B]

Is an electric welder needed for doing this?

 

[tw205]

Awesome ingenuity. I did something similar. I had bought a 95 FFR for parts but ended up reviving it for a daily beater. It had been vandalized and the cat had been hacked off leaving the cat flange with torn leavings of pipe. I removed it and managed to get it cleaned up to just the flange. Then a 3” pipe with flared end squeezed in a vice till it was oval and fit in the flange. Welded it in place and bolted it back on the Y pipe. Gave a great new round pipe to put things back together. Yours is much more refined. Nice work.

 

[Shran]

Is an electric welder needed for doing this?

Not necessarily, you could either find tubing or a cat that fits inside of the 2.5" end or either of those that fit over it and use clamps. Welding is ideal but clamps are OK too - might just require a couple extra pieces and/or having a piece flared out a bit at an exhaust shop.

Awesome ingenuity. I did something similar. I had bought a 95 FFR for parts but ended up reviving it for a daily beater. It had been vandalized and the cat had been hacked off leaving the cat flange with torn leavings of pipe. I removed it and managed to get it cleaned up to just the flange. Then a 3” pipe with flared end squeezed in a vice till it was oval and fit in the flange. Welded it in place and bolted it back on the Y pipe. Gave a great new round pipe to put things back together. Yours is much more refined. Nice work.

I also tried the 3" pipe trick, that is certainly less seams to weld but then you have to reduce it. I'm not sure my way is really better, but it works, basically I take two 4" pieces of 2.5" and cut one in half down the sides, tack that to the flange and then stick the other 4" piece inside those & tack it. Then flatten out a piece and make little pie shapes to fill in the gaps, weld it all together & you're done. It's a lot more seams to weld but it works OK.

 

[tw205]

Not necessarily, you could either find tubing or a cat that fits inside of the 2.5" end or either of those that fit over it and use clamps. Welding is ideal but clamps are OK too - might just require a couple extra pieces and/or having a piece flared out a bit at an exhaust shop.



I also tried the 3" pipe trick, that is certainly less seams to weld but then you have to reduce it. I'm not sure my way is really better, but it works, basically I take two 4" pieces of 2.5" and cut one in half down the sides, tack that to the flange and then stick the other 4" piece inside those & tack it. Then flatten out a piece and make little pie shapes to fill in the gaps, weld it all together & you're done. It's a lot more seams to weld but it works OK.

Your welding skills are far superior to mine. But I try.

 

[Uncle Gump]

I too have used 3 inch smooshed to fit and welded with a reducer.

Had one of these been available... total easy button.

Your offering looks good...