Piston Slap: Reproduction Exhaust Systems for Obscure Classics

George writes:

I own a 1961 Econoline, and I want a reproduction exhaust system for it. The short block is a 200 CID six, probably from a Falcon. The part numbers show it dates to 1967. The head dates from 1974, so it’s probably from a Maverick. A previous owner installed a “hot” aftermarket exhaust system. Since the engine is right beside the driver, this makes the Econoline very loud. (The stock exhaust is bad enough!)

I’m having trouble finding parts to complete the new exhaust system. I have the new muffler and have a source for 18″ pieces of straight pipe. I need to find an exhaust flange gasket and pre-bent 1.75″ pipe.

Sajeev answers:

George, are you building this reproduction exhaust system yourself? Those pre-bent parts at correct lengths and contours are generally impossible to get off the shelf. They usually come in shapes like “U”s that are meant to be cut to the correct angle and welded together to fit. So instead, check out Waldron’s Exhaust, a place that actually makes a kit for your Econoline.

But let’s discuss the obvious solution seen around town: Local exhaust (or muffler) shops can make just about any exhaust system. They usually modify off-the-shelf raw materials to conform to the unique confines of a specific vehicle, meaning you are at the mercy of the staff and management to ensure a quality product. And that’s why local exhaust shops are hit-or-miss, as I learned when looking under the Mehta family’s prized 1985 Ford Thunderbird.

I am glad I didn’t have my smartphone when working under the Thunderbird, because every pipe was butchered to the point you wouldn’t believe it had only 30,000 miles. After 20+ years of Garage Queendom, those sloppy welds turned into a leaky mess. Everything had to go, aside from the factory exhaust manifolds that bolted to the engine.

With a lot of bends for a unit-body platform and two catalytic converters, I assumed nobody would reproduce this system. I was on the verge of going to my trusted exhaust shop, as they made a good cat-back exhaust using bits cobbled together from Walker Exhaust for a Lincoln Continental that I call Foxy Brown. But the Thunderbird was also a hot mess and had a complicated Y-pipe. I wanted something better, if possible.

All it took was a Google search, a phone call, and the hope that Waldron would take my project seriously. I braced myself for the usual “No, we don’t have stuff for cars that new,” but I was pleasantly surprised at their willingness to take on the challenge.

What you see above is the first Waldron’s Y-pipe exhaust for Fox Chassis Fords. It comes with factory-sized pipes, correct bends, catalytic converters, pipes for receiving air from the smog pump, and a new muffler that sounds a bit deeper than stock.

This was no small feat. They found the original templates, created jigs to replicate the system, and charged a reasonable price for the end result. I had it in my hands after six months, but it was absolutely worth the wait. Upon installation, my exhaust guy noted Waldron’s system was easy to install, and he thanked me for finding such a nice setup that made his job so easy.

While I’m leery of flat-out recommending a company* here at Piston Slap, sometimes it’s the right thing to do. Unhappy experiences posted online aren’t enough to dissuade me, not to mention I used their product to test the durability of the Rivian R1T’s plastic bed for a Hagerty review. (It did a great job gouging the soft plastic bed liner: Waldron’s 1, Rivian 0!)

George, I would call Waldron’s first. If they offer no joy, get a local exhaust shop to bend the tubes accordingly.

*I paid full price for my reproduction exhaust system. No quid pro quo with this automotive journalist! (If there was, Waldron’s must be upset that it took three years to reciprocate.)

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