Conversions & Hybrids - Crossmember install fail

Here is a pic of the crossmember I had installed at a "custom" shop. I didn't realize that there is no room for the exhaust until I was on my way to the muffler shop until I thought about it. I guess I will have to section the crossmember and install a piece of square tubing for exhaust. Anybody have any suggestions besides aftermarket crossmembers? 74 Nova 6.0/4l80e
http://i189.photobucket.com/albums/z169/poisonivy514/crossmbr5.jpg
http://i189.photobucket.com/albums/z169/poisonivy514/crossmbr4.jpg
http://i189.photobucket.com/albums/z169/poisonivy514/crossmbr3.jpg
http://i189.photobucket.com/albums/z169/poisonivy514/crossmbr2.jpg
http://i189.photobucket.com/albums/z169/poisonivy514/crossmbr1.jpg

Get some thick u-channel and weld a section in. Should give u some room to sneak exhaust through

What size exhaust? Use next size larger schd 40 pipe and cut 2 sections out of x-member and replace with the pipe. Heres what I did.

http://i583.photobucket.com/albums/ss278/01ws6bird/PICT0085.jpg

Damn your driveshaft looks short

Can you run it under? Does the car sit high enough?
http://i50.tinypic.com/w9zi9u.jpg

It's 3" exhaust. I'm gonna try and find that schd 40 pipe at home depot, may me able to get by with that.

The 4l80e sits pretty far back so I had the D/S shortened quite a bit.

Definitely not enough room to run it under. Im at about 8" clearance, if that.

why is the diff backwards ?????

It's 3" exhaust. I'm gonna try and find that schd 40 pipe at home depot, may me able to get by with that.

The 4l80e sits pretty far back so I had the D/S shortened quite a bit.

Mine is 3" also, our home depot definitely does not carry schd. 40. You might try a metal recycler or even ebay you can buy 12" lengths on ebay. You can even you steel tubing .187 or .250 wall.

What is the outside diameter of the pipe for 3" exhaust pass thru

You can get whatever size you want at metalsdepot.com It will cost you about $20 plus shipping for 4".

http://www.metalsdepot.com/products/hrsteel2.phtml?page=pipe&LimAcc=$LimAcc

What is the outside diameter of the pipe for 3" exhaust pass thru

For 3" you can use 4" pipe OD is 4.5 ID is appx 4", or you can use 4" tube (4" OD) with a wall thk of .187 ID appx 3.625". I have V-bands on my exhaust and the flange just passes thru the 4" tube, another option is to cut the pipe in half and cut a half circle in your x-member and fill the half circle with the pipe half, thus making an opening for your exhaust to tuck up into.

I just welded in extensions on the old brackets on the frame where my crossmember originally mounted, and then used the original crossmember.

You can see the extension we added near the saw blade in this pic:

http://i173.photobucket.com/albums/w41/lordguyton/ls36.jpg

why is the diff backwards ?????

It's not backwards, that is a 9" or 8.8" housing without the 3rd member, Axle are in place, nothing else.

They are not like a GM 10 or 12 bolt housing.

BC

Damn your driveshaft looks short

I'm thinking the same thing.

"The 4l80e sits pretty far back so I had the D/S shortened quite a bit.".........Looks to me as tho it's about an 1" too short.

06TBSS has the right idea. You can get a piece of 3-1/2 inch SCH.40 (4.00 OD X .226 wall) cut to 1' long from metals depot for just under $20.

I would make it like the one in the pic.. Leave a long enough straight section to move the crossmember incase you have to pull Trans.

That diff is not backwards..:lol:..that would be a 9", 8.8 is setup like a GM 8.5.

Good call on the Sched. 40. I picked up 2' from the scrap yard for $9. Its 4" pipe, but I i am going to half the pipe so the exhaust will just fit up in the half circle. Harbor Freight had a sale today so I was able to pick up 4.5" cut-off wheel to do the work. I also picked up some .023 to do the welding with gas shield. The main reason I had someone else do it was because of the welding, i'm not confident enough to do a structure piece, but I guess I will have to. I have a 220V welder so i'm sure its capable.

The Driveshaft is a little short, but it has plenty of engagement. I gave the shop the length with the 1" subtracted already, but they subtracted another inch.

Good call on the Sched. 40. I picked up 2' from the scrap yard for $9. Its 4" pipe, but I i am going to half the pipe so the exhaust will just fit up in the half circle. Harbor Freight had a sale today so I was able to pick up 4.5" cut-off wheel to do the work. I also picked up some .023 to do the welding with gas shield. The main reason I had someone else do it was because of the welding, i'm not confident enough to do a structure piece, but I guess I will have to. I have a 220V welder so i'm sure its capable.

The Driveshaft is a little short, but it has plenty of engagement. I gave the shop the length with the 1" subtracted already, but they subtracted another inch.

That is carrying a good portion of your engine trans weight, .023 is for body panels, .035 would be a better choice, at least in my shop...
my .02:usa: