I purchased one of Brad Merricks exhaust systems without rear muffler as my standard XU1 1985 manufacture muffler is good. Brads system come with a resonator just below engine pipes as per original factory whereas my current system does not have one fitted. I also have to fit the original GTR front sway bar at the same time, as the car came fitted with a K Mac front sway bar which I removed to bring it all back to original. My question to the forum members is what sort of drama am I likely to encounter fitting all this up to the standard XU1 headers is the resonator going to hit/touch the sway bar. If my memory serves me correct the front sway bar and resonator nearly touch each other. Any tricks before I crawl under there? Do I fit the sway bar first then exhaust or other way around? Is it best/easier to go to an exhaust shop?
Fitment of new XU1 exhaust
Posted 09 October 2019 - 10:21 PM
You shouldn't have any dramas fitting the system.
But first some important advice regarding the stabiliser bar fitment. It is paramount that it is fitted with the suspension "at rest" ie. the car sitting as it normally does on the ground. That means using a four poster hoist or car ramps to raise the front of the car enough to be able to get under and do the fitment.
Fitting while the car is on a two poster hoist or similiar with the suspension hanging down means the bar is put under too much torsion once the suspension has returned to normal position.
The end result will be a broken bar - an expensive lesson these days!
If the bar is already off, leave it off until the exhaust is fitted.
Brad's systems were all test fitted to my LJ XU1 (except the LC header/engine pipe - but the same LJ manufacturing jig was used). They were all fitted on a hoist without removing the stabiliser bar.
Brad's systems have all been made using NOS originals as patterns. As you have said, the original factory header/engine pipes used to rub/knock the stabiliser bar- very annoying. During re-manufacture, the pipes were raised about 1/2" over the stabiliser bar to eliminate this problem so you won't have any clearance issues.
To fit, loosely assemble the whole system to the car and adjust the pipes and muffler into the correct positions to give proper clearance. Once this has been achieved tighten everything up.
I am currently running his '73 Bathurst system on my car.
Posted 10 October 2019 - 12:15 PM
Thanks for the comprehensive and helpful advice JPXU1. I knew about the sway bar fitment trick so will definitely have it sitting underload.
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