DIY Network

1962 Fort T-Bird: Exhaust-System Upgrade From "Classic Car Restoration" episode DCR-304

From the amount of rust and wear on the T-bird's existing exhaust system, it's pretty evident that replacement -- or better yet, an upgrade -- is in order. We replaced the worn-out system with a new, high-flow exhaust that also helps boost power.

This segment provides a summary of the exhaust-system upgrade on the 1962 Ford Thunderbird. Auto-restoration expert Keller Wallace joins host Steve Magnante to help out with this phase of the project. As mentioned in the segment, much of the installation work was performed by professionals at a muffler shop. The preparatory steps and procedures that we performed are outlined below.

Materials:

Standard automotive tools (socket wrenches, extensions, combination wrenches, screwdrivers, nut-drivers, etc.)
Air compressor; impact wrenches and cutting tool
New exhaust kit
Jack and jack-stands
Floor-jack
Rags

Safety Equipment:

Work gloves
Safety glasses or other eye protection

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 on 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.

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	Figure A
	Figure B
	Figure C

Ford specified a 1-3/4-inch dual exhaust for the original '62 Thunderbird, but considering that the car has a 390-cubic-inch engine, that size piping is rather small. Since an internal combustion engine functions partially as an air-pump, the more air that can be moved through the system, the more power can be produced. Rather than replacing our exhaust system with a historically accurate 1-3/4-inch system, we opted to upgrade to 2-1/4-inch tubing for added power.

• With the T-bird on the lift, Keller used a pneumatic cutting wheel to cut off the old exhaust system (figure A).

  Safety Alert: Always wear eye protection when working with power tools or pneumatic tools.

• Provided that you're not planning to re-use the old exhaust system, there's no real trick to removing one. Simply cut off the brackets, then cut off sections of pipe, and the muffler, and remove them as you go (figure B). The best tool for this job is an air-powered cut-off tool or a die-grinder with a cut-off wheel. These tools are available with straight shafts angled shafts for accessing hard-to-reach areas. Some are made with the cutting wheel mounted parallel to the shaft for tight areas.

• We left about one foot of the old exhaust pipe on each of the exhaust manifolds (figure C) to ensure that we didn't damage or disturb the aged studs and nuts that hold the head-pipe to the manifold. The muffler shop where we took the car for installation of the new exhaust system had the proper tools (torches, nut-splitters, etc.) to pull the studs apart safely, without damaging the engine.
  

  	Figure D
  	Figure E

  
  
• Once the T-bird came back from the muffler shop, we inspected the new exhaust system. Replacing the old system with two-inch exhaust piping (figure D) and simple turbo twin-mufflers (figure E) results in better exhaust-flow capability, increased power and a pleasing "rumble" from the powerful 390-cubic-inch engine. Local muffler shops and national muffler-service chains can typically handle this type of installation at a reasonable cost. In our case, the cost of service for the installation was about $200.
  
  

RESOURCES :

Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
Order this book from Amazon.com
Haynes Publishing

The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books

Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896

Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners and Restorers of Classic and Collectible Automobiles
1557881944
Jim Richardson
(November 1994)
To order this title from Amazon, click here.
H.P. Books