Still plenty of dust there Jonesy.
Well I have more than enough parts now thanks to Christian.
The old exhaust is ready for the bin
The first problem was the end bits are longer than my previous ones. The clamps from the old exhaust helped but I still needed to get longer stud bolts to accommodate this.
Probably the most surprising issue I had was that the headers would not line up in the collector. I mucked around with this for some time before I decided to adjust the collector box to suit the way the headers came from the block. Not sure how well the pictures show this but either the inner pipes needed to be longer or the outer pipes needed to be shorter, also the angle was some what out as well. I would be interested to know if there is any difference between the blocks from the XS to the XJR or if this was just an anomaly of mine? Anyway I am now very happy that the collector and headers go together pretty easy and I don't believe the flow will be considerably upset.
The pipes are a very snug fit in the exhaust outlet, this shows how the pipe was too long on the out side exhaust.
Here the pipe would just not go into the collector box any more.
This cut allowed the position to go down and change the angle as well.
Ok now we're back on track, Mad Bill cut the collector box top and bottom to adjust the angles. I saw no reason to do it this way and it causes a large gap on the outside of the bend. It is much better to cut say all of the inside bend and then all of the two sides leaving the outside bend intact. This way the bend closes in on itself.
Like this,
Then when tacked together there is no gap to fill.
And again with the muffler end. Just cut the inside of the bend and leave it connected at the top. This closes in on itself leaving no gap.
Almost there, I ended up getting the collector box a little closer than this in the end.
Just need to double check everything in the morning and weld it up.
