Waiting on some exhaust pipe flanges that (hopefully) won't leak. They're called Marman flanges and are made from stainless tubing with an end former. They use off-the-shelf V-band clamps. The shop owner had some issues with incorrect dimensions; corrected parts should be here by end of week.
Since the welds are located further away from the flange than the common "V-band" machined flanges, these shoudn't warp nearly as much.
EDIT: Just received some supposedly corrected parts on 3/28/19. The original set didn't clamp together properly and were still loose after tightening the clamp all the way. They replaced the female flanges and were supposed to be better sized, but they're basically identical to the originals. Returning these and going to try something else. What a disappointment - spent about 6 weeks trying to get a batch of these that would work. Maybe they will straighten out their manufacturing process eventually; but for now I'd recommend you not waste your time with these.
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I've learned that idle hands (like when waiting on parts) makes me more likely to add silly mini projects to this swap. Decided to run the tail pipes through the rear crossmember (and eventually the bumper). With the body lift, I'll be able to tuck the mufflers higher and nearly flush with the frame rails. May as well take advantage of the extra space. This should help protect the exhaust tips from getting smashed on the trails. Plus, I figured if this mod doesn't work out, I can cut it out completely and go with one of the crossmember replacement options.
For the crossmember clearance holes, I'm using Sch. 40 ASTM A-500, 4-1/2" od x ~4" id, 4" length. Welded in with stick 6011.
. Guess JKO can't take the really long ones haha...
