performance exhaust for '91-'94 Sport 2 door

[FordKawaHauler]

Does any company make a performance exhaust system for a '91-'94 Sport 2 dr? I've seen Sports online with Borla exhausts but I can't find one anywhere, the only exhaust i can find for a '91-'94 Explorer is for the 4 door, any help will be greatly appreciated.

 

[CONavajo]

I have a cat back Flowmaster system on my Navajo, same as the 91-94 Sport. Bought it about 4 years ago though, not sure if they still make it. Got it from Summit if I recall correctly.

 

[410Fortune]

you can get the Borla kit and hack out about 24" of it.

However your best bet is to just have your exhaust done at a local exhaust shop. Stainless if you want, but thats big bucks.

On my BII (shorter then sport, similar problem, lots of ranger kits, nobody makes it for my wheelbase) I had mine built, very similar to your sport (dont forget I have an Explorer drivetrain)

from the Headers back I had a custom Y pipe built to fit my custom auto tranny, then 2.5" pipe into a 2.5" high flow cat, out straight shot into a single in, single out 2.5" Magnaflow muffler, straight out the back 2.5"

Works great with teh OHV 4.0L and all my intake mods.....

 

[Webster3]

This is something I'm planning to do eventually... my shields are all rusting off and I'm sure I'll see holes soon enough.

Is the Catback a lot louder than stock? I'm just looking for a long life and a nice deep throughty sound without it being really loud.

Ed

 

[410Fortune]

Ask Brett Grooms, he welded a Flowmaster muffler into his stock Sport exhaust and it sounds great!
Not near as loud as my truck but his 4.0L is stock and I know it sounds great.........

 

[Rhett]

You can always buy whatever muffler you want (Borla, Flowy, Magnaflow, Thrush, Cherrybomb, Gibson) and then have a shop do 2.5" mandrel bent pipes. This is what I did. Essentially, I got a cat-back for $150. It's easy for a shop to do this, they have pipe benders and the whole 9 yards.

 

[410Fortune]

Rhett be careful, mandrel bending is something only a few select shops can do, in fact I have only found 1 place in all of Colorado that can do it.

However you dont really need it for an Explorer, the bends a typical exhaust shop can do flow just fine....we are not talking 10 second 1/4 mile track cars here, or forced induction.

I paid $450 total to my exhaust guy including new cat and muffler with custom hangers and 2.5" pipe from the Y pipe all teh way back.........not a bad deal.

Now on the other hand Borla Stainless exhaust systems are VERY HIGH quality, in fact I have never seen such a nice aftermarket exhaust system. HBut since they dont make a system that bolts onto a sport its a shame to buy one then hack it up........plus they are $$$$$$$$$$$$$$$$

 

[CONavajo]

Things have changed in the aftermarket support for our old dogs I guess. I remember deciding on the $$ Borla stainless system for my Navajo when I ordered the cheaper Flowmaster cat back. No longer available huh? Thats too bad.

My Flowmaster system sounds pretty good, many have mistaken that I swapped a V8 into it from the rumble it puts out. In fact, I just installed Borla headers and a Borla Y on my V10 Super Duty, had a shop do some custom links to the stock cat (no, they were not mandrel bent, didn't find the right shop!) and had a magnaflow muffler installed. Sounds like a VW Bus now, my Flowmaster 4.0 Navajo sounds way better.

410, What shop in CO did you find that can bend mandrel? I used Bud's per some advice on another board.

 

[Webster3]

I was on Flowmaster's site and it seems they do have something for 1st gen Sport. Is this similar to the model you have?

Flowmaster for 1st Gen Sport

Ed

 

[hvac man]

I had a custom "mandrel bent" exaust built with a flow master 2.5 exit and it has been great for performance I spent about 350.00 for it though. I actualy felt the differance when I left the shop. I get one put on every vehicle I buy combined with a K&N filter and this was the most dramatic improvement of any of them.

 

[AlaskanJack]

I had a shop do my custom exhaust on my 93 sport. Flowmaster and I did a single in dual out set up for the time being soon it will be actual dual flowmasters from the cat-back

 

[Webster3]

So is the one I have in that link a decent system or is it really only a little better than stock? I'm guessing it is not a bolt-on system, so I'll probably have to get it welded if I were to buy it right?

Ed

 

[newbi]

Go with the Flowmaster cat back system for your 94 Sport 2 door. I'm assuming you have a 4.0. Got mine from bigexhaust.com delivered to my door for under $200. Bolted right on with no mods or welding required. Nice rumble and slightly larger intermedate pipe/tailpipe. Very satisfied with this product!

 

[Webster3]

That sounds good newbi. The only thing that is a little dissapointing is that its not stainless, but I guess when there's not much out there....

Ed

 

[newbi]

Its all treated tubing...been to the coast several times and no signs of deterioration. I did end up welding the pipes to the muffler instead of using the clamps.

 

[Rhett]

Ed originally I wanted stainless for my 94 Sport. But then I decided I'd rather paint the pipe black (with hi-temp paint) since I hate chrome, but yet I wanted something to protect the pipe. Plus I weighed cost of all stainless vs. aluminized pipe ($150 total vs $400+ total) and it's just not there. I'd rather blow my money on performance mods on my truck, and aluminized pipe works as good as stainless.

 

[Webster3]

Thanks for the advise guys, sounds like the stainless isn't really worth the extra bux... I just want something that will last and sound good and won't break the bank and it sounds like this Flowmaster might be my ticket.

Ed