Okay so I took the grinder to the tail pipe and cut off the old bracket. Then went to Advance Auto and bought a multi-hole exhaust hanger that would allow me to adjust the length of the front hanger. Once I had it at about the right height to line up with the muffler/cat output, I marked where the J hanger would go on the back. Quick welds on both sides of the hanger and it was fine.
All that remains is affixing the muffler to the fail pipe, and pressing the gusset between the cat and the muffler.
What are the various sizes that need to be mated again?
The OD of the muffler is 2.75 inches, the ID of the catalytic is 2.25 inches. I do believe I found the solution last night though, in the box that the cat came with. It included a rubber-like material "doughnut" that fits around the cat, and that is tight, but most likely possible to fit inside the Banks muffler. This would seal that off (pending an exhaust clamp over it). Meaning all that's left is fitting the tail pipe back into the muffler.
I hope you got it figured out! I hope those pics i sent helped a little haha. When i did mine, i had to buy new exhaust hangers to tighten it up because it hit my trailer hitch every two seconds, not it only occasionally hits when im in first gear and make a sharp turn and my RPM's get kinda low. I think i might take the tip off and see how it is.
Work continued yesterday on the single most annoying project I've ever done. I HATE EXHAUSTS.
I rented the "exhaust flanger" from AutoZone for freeeeee which spread the muffler output open far enough for me to get it back onto the tail pipe smoothly. Well worth the time to do it, and a VERY cool tool. Then, since there were no adaptors to get from the muffler to the cat at Advance or Auto Zone, I made one. Bought 2 different ones that fit each part respectively, cut them and re-welded them together. I was then finally able to get the two to bolt up, and am now only waiting for the O2 sensors.
Oh c'mon exhaust is fun lol
If hair pulling, swearing about how something is welded wrong by the manufacturer, and generally hating how as soon as its all done its going to get crushed on a rock is fun to you
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"Redneck Rooster" 98 TJ with 5.3 Vortec, 4 speed, 37"s
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"Bullfrog" 88 XJ 4.0, Doorless, 2" lift, 33-10.5 tires, very cut fenders...