DIY Network

1965 Mustang Restoration: Install Performance Exhaust System The Mustang's rusty exhaust system get's replaced by something with a little more flash — and that moves a lot more air. From "Classic Car Restoration" episode DCR-505

In this phase in the restoration of our '65 Mustang fastback, Steve improves the original exhaust system by installing a performance exhaust system with larger pipes and performance mufflers.

In this particular project, he continues the exhaust system upgrade by installing a performance dual exhaust system. The new headers and exhaust system complement the improved air intake system in the engine and add performance and horsepower to the Mustang.

The basic steps in this part of the restoration as seen in this episode of Classic Car Restoration, as well the tools and materials required, are summarized below.

The new mufflers and exhaust system, installed

Steve installing the new exhaust system

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	The new dual-exhaust system components
	The new performance mufflers
	The mounting hardware for the exhaust-upgrade.

Tools and materials used in the exhaust system upgrade:

hooker headers (1-7/8" diameter)
new exhaust system
penetrating oil
full set of wrenches/sockets
2 performance mufflers
mounting hardware
H-inlet pipe section
full tailpipes
jack and jack stands
safety equipment

Note: This is a summary of steps included in the automotive restoration procedures shown in this episode of Classic Car Restoration. These are general guidelines for restoration procedures on this particular make and model of vehicle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

Safety Alert: As a standard safety precaution, don't rely solely on a jack to support the weight of a vehicle. When using a jack to access or work beneath a vehicle, always use jack stands for support. Make sure that the jack and stands that you use are rated for the weight and type of your vehicle.

Safety Alert: Always wear eye protection and follow proper safety precautions when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle.
Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

	Steve installing the new, larger gauge exhaust pipes

Steps:

H-Pipe Section

• Start by installing the mounting bolts and gaskets onto the two outlet pipe flanges of the new headers.

• Put the H-pipe section up, and use a jack stand to steady the back of it.

• You may need to modify your inlet pipes with an adapter to fit your particular headers. That can be done by a local muffler shop.

• The mounting flanges slide into place at the header outlets.

• You may need to adjust the jack stand and pipes to adjust the flanges flush with the header outlets.

• The nuts are installed onto the mounting bolts and tightened down to snug for now.

• It's important to leave clamps and brackets loose until all of the exhaust sections are installed and fit properly.

• With the "H" section in place, the muffler clamps go on, the mufflers slip onto the H pipe tails, and the clamps slide into place.
  

  	Steve installing the new mufflers

• The front muffler hanger brackets are fitted on to mark the bracket positions on the underside of the floor pan.

• Tip: It's always a good idea to use a nail punch to create a dimple in the metal before drilling.

• The mounting holes are drilled out. You can use a step drill bit, which creates as wide a hole as needed.

• From inside the car, install the mounting bolt bracket.

• Install the hanger bracket, washers and nuts underneath the car.

• Do the same for the other side mounting bracket and tighten down and secure to the floor pan.

• With the brackets secure, the hanger is installed, sliding the rubber hanger over the mounting bracket rod and securing the clamp over the muffler outlet pipe.

• The tail pipe can now be installed slipping it over the axle onto the muffler and securing the rear to the existing tail pipe hanger.

• Install the other tail pipe and secure it to the existing hanger bracket.

• With everything fitting well, go back and tighten down all the brackets and clamps.

RESOURCES :

Special resources for DIY's Classic Car Restoration 500 series: 1965 Mustang

Mustang Club of America
www.mustang.org

Mustang Central
vintage Mustang parts
www.mustangcentral.com

Motorbooks Publishing
www.motorbooks.com

Class-Tech-Cars
www.class-tech-cars.com

Holley Performance Products
www.holley.com

Flowmaster Exhaust Products
www.flowmastermufflers.com

Genuine Hot Rod Hardware
www.genuinehotrod.com

Revelation Racing Supply
www.rrs-online.com

National Parts Depot
www.npdlink.com

Classic Auto Air
www.classicautoair.com

Pertronix Performance Products
www.pertronix.com

Stainless Steel Brake Corp.
www.ssbrakes.com

Painless Performance Products
www.painlessperformance.com

Loctite Products
www.henkel.com

Paintucation
www.paintucation.com

Dupli-Color Paints
www.duplicolor.com

Norton Abrasives
www.nortonabrasives.com

Dremel Tools
www.dremel.com

Classic High Performance Audio
Product: audio equipment

Direct Source
www.the-direct-source.com
Product: stereo electronic equipment

Dakota Digital Instruments
www.dakotadigital.com
Product: digital dashboard

Mustang Project
www.mustangproject.com
Product: LED sequential taillight system

Memory Lane Collector Car Dismantlers
vintage and salvage auto parts
www.oldautoparts.com