When installing a new Exhaust How do you go about aligning everything

Let me preface this with the fact that, save for my muffler which is a stock OEM, I have an all fabspeed system. Another make or OEM components may not work exactly the same.

I start with adjusting the flanges on each header so the donuts have the header pipe fully inside them to provide support and prevent them from being crushed/distorted when tightened. This also goes a long way toward eliminating any leaks after everything has had a chance to seat. My Fabspeed headers and the flanges, while very tight fitting, can be tapped forward and back to facilitate this. This is true for both the Y pipe and the cats (or test pipes in my case).

Next comes the muffler/Y pipe. I place my OEM muffler centered in the car so the tips fit into the bumper slots the same on both sides, they protrude the same on each side (the adjustment to accomplish this explained later) and adjust the spring supports accordingly to allow this while standing perfectly vertical. The valve now goes in place but not tightened fully. Ideally, everything should automatically be centered in the car, muffler, valve and Y pipe valve connection. If not, the Y pipe to muffler connection can be adjusted a tiny bit left or right by adjusting the header flange on one side only to slightly rack the pipe but only slightly or the muffler tips won't protrude the same. This is not desirable but possible to correct a slight off center misalignment. Since I have a Fabspeed Y pipe, I had them put adjustable sleeves on each side in the straight sections as they come up to the valve connection to provide adjustment that permits perfect alignment here. Since the sleeves slope downward on each side from the valve connection, as the Y pipe center section is moved either left or right to find the exact center, the header sections on each side slide on the sleeves while at the same time rotate slightly up or down on the donuts which raises or lowers them to make up for the sleeve slope.

Next, the cats or cat bypass pipes are fitted into the muffler (they were already installed but not yet fully tightened). The amount the tips protrude from the bumper is controlled by pushing the muffler forward or back by adjusting the Y pipe header flange positions . (I set mine about 3/4" out at the top). Since the connection at the valve has no adjustment (save for the sleeves I had installed which won't be of any help here), the muffler/valve/Y pipe as a rigid assembly must be rotated together upward or downward, "hinged" at the donuts, to get the tips to fit into the bumper slots at the desired height ( I set mine at about the halfway point). The muffler support springs may need to be readjusted at this time to remain perfectly vertical.

Last, slide the OEM adjustable cat/test pipe flange to fit up to the muffler and place the clamps over the pair but don't tighten them fully yet. The cat/test pipes can be axially rotated a bit at the donuts if needed to adjust for the "tilt" of the muffler/Y pipe assembly.

Check everything to make sure its all adjusted correctly and then tighten all the connections fully. I don't think I've left anything out so I hope my explanation helps and it makes sense.

 

Depends where your leaks are.