LT1-LT4 Modifications 1993-97 Gen II Small Block V8

New 409SS 3" single exhaust

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Old Nov 18, 2016 | 12:50 PM
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Default New 409SS 3" single exhaust

Not much traffic in the LS section on this but figured I would also share with the LT section since my car is a 95.

Car originally came with PS catless Y pipe and Borla adj catback. It has since gone through a modified Borla catback, then tried to "fix" the merge in the PS midpipe.

First midpipe change in an attempt to smooth the merge. You can see the original merge here:



Tried to cut off as much as I could and stuff on a 4" dia Flowmaster "race" muffler followed by a 3" glasspack:



Placed an order for some pipe and 3" Vband:



Couple days later planning this out I came up with this. My friend had a good idea for a better Y merge design.





I took the old exhaust off last Thursday and had a fully mocked up/tacked system last night ready for welding. All work was done with the car on jackstands and nothing more than a 4" electric cutoff wheel and a tape measure. The dark areas are where I needed to heat the pipe to dent it for clearance. The DS dent is for the typical LT1 floorboard area. the other area is for the TA clearance.

I have a Watts Link and can confirm that the V-Band rings can be removed between the floor and Watts link. the goal is to have the rear section removable to run a full size muffler for winter to be quiet then swap out for a more aggressive system for summer.

Exhaust is currently welded and I plan to get it on the car and running by tomorrow.

Update: Videos of both setups

Last edited by smitty2919; Apr 21, 2017 at 01:57 PM.
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Old Nov 18, 2016 | 09:37 PM
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That looks great and I bet it'll sound great too. Be sure to post a video clip of it when you get it on.
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Old Nov 23, 2016 | 07:55 AM
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This system turned out great. My old system had some popping going on low rpm high load with a glasspack style muffler. With the new system and the same muffler, the popping is cut down DRASTICALLY. It has a hint of LS motor tone now.

This is the popping I was trying to get rid of at the 0:24 mark and 0:57 mark.

The new merge REALLY smoothed that out. I will never build a conventional merge again.

I will work to get a video this weekend.
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Old Nov 23, 2016 | 08:57 AM
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Sounds great!
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Old Nov 23, 2016 | 10:27 AM
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Originally Posted by n2oblkz
Sounds great!
That video was the "old" modified PS Y-pipe...IMO the new system is smoother/better.

During the process...Old vs New:


Installed:




Tip will be remade to mimic the MUFFLEX style hidden tip.

Last edited by smitty2919; Nov 23, 2016 at 10:53 AM.
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Old Nov 23, 2016 | 11:11 AM
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I'm curious to hear the new setup
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Old Nov 26, 2016 | 01:46 PM
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Added video to OP
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Old Nov 26, 2016 | 02:23 PM
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Sounds great
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