1957 Chevy Bel Air Exhaust System - A Tale Of Two Tailpipes

1957 Chevy Bel Air Flowmaster Exhaust System Install

So far so good. The H-pipe is in place and the mufflers are coming next.

Perhaps the best part of this particular system is the fact that the pipes are already flared, including the inlet and outlet of the mufflers. We don't have a pipe bender or flaring tool in the Primedia Tech Center, but one was not needed during this install. It can all be done with careful measuring, cutting and welding.

With both mufflers being held in place with stands, they're tacked into place.

Before we went any further, the exhaust system was unbolted from the headers and the tack welds were welded in and filled. After it was completely welded, we reinstalled it and were ready to attach the brackets to the rear of the mufflers. Up until this point the install has gone fairly smooth-time consuming, but smooth. The last half from the mufflers to the tailpipes seemed to require the most cutting and test fitting.

With everything back in place and supported, it's time to add the exhaust brackets. Drill into the support brace, and then thread the hole with a tap and die set. After this is done and the exhaust is hung, the support stands holding it all up can finally be moved.

It's at this point in the install where it can get a little difficult. This is how the Flowmaster pipe looks as it came out of the box. It should clear most axles, but we wanted our install as tight and close to the frame as possible. That means we had to change the geometry on it. You may notice the difference between the left side and the right. The right side has already been cut and installed, while the left side is still uncut and can hang below the leaf springs. We don't want that, so it's time to do some more measuring and cutting.

After the mufflers are hung and clamped, this is the last of the straight pipe to be installed.

After the cut, everything is tacked into place, then checked and rechecked to make sure it will all work.

We won't put you to sleep by documenting every cut and weld that goes into a custom-fit exhaust. After we are satisfied with the geometry and the angle of the dangle, the last and final straight piece is added.

And just like we did with the mufflers, the vehicle support brace is drilled and tapped in order to hang the exhaust brackets.

We didn't have any exhaust tips to add, but will put some on later. Take a look at how even both pipes look as they exit out from under the bumper. The extra effort it took to get that tight fit paid of in the end.

Success! The bracket is bent to hold the last section of pipe and welded-and we are done like dinner. That wasn't so hard, was it? Well, it wasn't a complete walk in the park. But if you notice, we didn't bend or flare one piece of pipe. What does that mean? If you really want to save some bucks, you can do this at home provided you have all the right tools and time at your disposal.

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1957 Chevy Bel Air Exhaust System - A Tale Of Two Tailpipes

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