Steve modifies his metal exhaust donuts by grinding one side to create a flat surface (left). He says this seal will outlast the standard fiber gasket used in most applications.

With the swager tool, Steve expanded a 2.25-inch sleeve just enough to make a nice snug fit inside the exhaust header. Keeping the metal doughnut around the sleeve ensured the desired diameter.

On the left is the old pipe with a conventional gasket. On the right is Steve's version with the half donut and flared and sleeved end.

Here is a good look at how the flared pipe, metal donut, and sleeve fit into the Ford cast-iron headers. "You can do this without the sleeve going inside the header," Steve notes, "but I like to do it with the sleeve going in at least 1 inch for added strength and less chance of an exhaust leak."

Patrick and Steve made sure the angle of the tube was exactly where they wanted it before tightening down completely on the header flange.

The section of pipe leading from the header/exhaust manifold under the car is critical, since it has to clear steering components but still tuck up high enough to keep from dragging on the ground.

Steve uses this vintage Haberle cold saw for precise pipe cutting. Making sure to cut the bend in the correct place is one of the most important elements when doing a custom installation.

Patrick and Steve mocked up bends and cuts and then tack welded the pipe in place to make sure it took the planned route through the chassis. The whole system was done this way to make sure both sides of the exhaust system measured the same.

One nice thing about the Hushpower II mufflers (besides the sound) is their compact size, which makes them easy to fit in vehicles with limited space or, in the case of the Galaxie, low ground clearance. Steve located ours just ahead of the kickup for the rear axle.

Considering the Galaxie's low stance, Steve took extra caution to make sure the pipe was routed high enough over the rearend, but was also careful to avoid putting it too close to the floor, which could create heat or vibration issues.

Here's a look at how the rest of the system was mocked up from the axle to the rear bumper.

After all of the pipes were cut and pre-fit on the car, they were removed for final welding. Steve demonstrated the TIG welder on a few sections to show the accuracy and clean look it delivers...

...It costs more for a custom TIG-welded system, but it's an option many Welding Works customers seek for the ultimate clean look.

Patrick welded everything from the mufflers rearward using a more common MIG welder.

When completed, the two sections of tailpipe (from the mufflers rearward) looked like mirror images.

Steve was able to re-use some of the hangers from the old exhaust, and installed new ones where necessary. He's shown here preparing a hanger that will support the rear of the muffler.

After determining proper fit and locations, the hangers were welded to the new exhaust pipe.

As Steve took care of one of the final welds supporting the tip, we got a better look at where the exhaust tip exited under the bumper. As planned, it was barely visible once the car was off the rack and resumed its stance.

Here is a good look at the finished product. The system is cleanly routed and tucked up tight where it should be, while the larger-diameter pipe and Hushpower mufflers give it the assertive exhaust note we were looking for. The free-flowing exhaust should also help make a little more power, and possibly even get better mileage, too. Wanna hear how it sounds? Log on to www.customrodder.com for a sound bite.