After over a year of on/off working on the car I drove it out of the garage...and it was noisy! I jacked it up and found holes in both mufflers, a hole in the "over the rear axle" pipe, and the catalytic converter.

I checked prices (around $1000 for catalytic converter and muffler!) and availability for a new exhaust and decided to put one together myself. I've ordered universal cat, an O2 bung, muffler, and mandrel bend tubing. My plan is to cut the downpipe just in front of the bad cat, weld in the tubing and cat, and extend the 02 sensor wire if needed. Then I'll have a shop bend some tubing to get to the rear where I'll run it to a muffler.

I'll document the build with photos. In my mind it makes sense. We'll see how it really works out. The shop that will bend the tubing is just up the street and awesome to deal with (small town shop). They will do the initial bend, then I can fit and return for tweak if needed.

 

My Summit order arrived today. Unfortunately my local shop can't bend 2 1/2 inch or larger exhaust pipe, so I'm looking for another way to get this done.

 

All my parts (45 and 90) elbows will be here tomorrow for a 3 inch exhaust post-converter. Photos will document the build.

 

Well, I got off to a good start. Unfortunately I broke my wrist today. It will be a few weeks before I weld again.

 

Update...And we're done! I now have a 3 inch exhaust from downpipe to tailpipe. I was able to do it with only a few modifications to the mandrel bent pieces.
I welded a universal 3 inch catalytic converter to a hacked off downpipe. It exits to a 3 inch pipe to the rear.
I went up and over the rear axle with 2 90 degree pipes (weld these together), extending the outlet by about 3 inches. Then it goes into a 45 and out to a zigzag section made from one 90 (weld these together). The offset inlet and center outlet muffler exits very close to center of the bumper cover opening.
I made hangers and welded them to pipes and muffler. I used hood prop rods for the hangers.

 

Last few photos of build. Easy on the weld comments...

All I need to do now is extend the O2 sensor wire, charge the battery, and cross my fingers.

 

The beast lives! Fired right up tonight and sounds good! Tomorrow I drop it off the jackstands and put it in the driveway.