Lets face it we all know how horrible they are, aside from just looking tacky, they almost never last. The U-bolt clamps are just as bad, you better hope you have them exactly where you want them because chances are, once you tighten them down they are sure to be rusted shut in a few weeks.
Here is a way to make your own custom exhaust hanger using one of those cheapo parts store hangers. Its simple, cheap, and even allows the whole system to be easily removed.
– Universal Exhaust Hanger with an open, pivoting end. (It must be this style, you’ll see why later)
– 1.25 ” X 1.25″ piece of 1/8″ steel
– 5/16″ or 3/8″ Thread bolt about 1″ long, lock washer, and hex nut.
– High Temp Paint (to prevent rust)
First you will need to cut the end of the exhaust hanger, with a Cut off Wheel, along the line drawn. This piece can be thrown out.
After the end is cut off you will be left with a tab sticking straight down.
Clamp the square tab to the hanger with enough room to drill a hole big enough for the bolt you are using, in my case it was a 3/8″ hole. Mark the center of where you want the hole to be and use a Center Punch to indent the metal so the drill bit doesn’t wander.
With the two pieces clamped, use a Step Bit to drill a through both pieces so the hole will remain in line. Pass the bolt through and tighten by hand so the tab remains square. Step bits make easy work of drilling large diameter holes, an essential tool when doing any type of metal fabrication.
Using jack stands or wire position your muffler or exhaust pipe in the location you want it to sit under the car. It is a good idea to determine where you want to mount the hanger to the body or frame of the car first, to insure the hanger is long enough to reach the pipe. (As an example I am using a piece of exhaust tube on a work bench and the hanger suspended from a piece of metal in a vice)
With the hanger mounted under the car, align your exhaust pipe exactly where you want it to hang.
Tack weld the tab to the exhaust pipe or muffler. Remove the supports holding up the exhaust and check the positioning.
If is where you want it, finish the weld along the tab. Allow the metal to cool off before unbolting the hanger.
Once it is cool to the touch, remove the bolt. Creating this custom exhaust hanger will cost about the same as using those tacky U-Bolts, and it makes exhaust removal a breeze. All that is left to do is a quick coat of High Temp Exhaust Paint and you’ll have a simple rust free solution to mounting your exhaust system.
Check out the Eastwood Blog and Tech Archive for more How-To’s, Tips and Tricks to help you with all your automotive projects. If you have a recommendation for future articles or have a project you want explained don’t hesitate to leave a comment.
– James R/EW