i did this a few months ago but i figured i would throw it up on here so people know it can be done fairly easily.

i am not a fan of the coffee can style exhausts and i was a big fan of the note from the thermal back in my 1G DSM days.

i had about 3' of 3" stainless tube, a 90* mandrel bent 3" stainless, and an old 1G thermal exhaust so i figured i would see what i could do.

i hacked up the thermal to salvage as much straight pipe as i could, and cut off the muffler after the down sweep to where it went under the axle of the DSM.

cut off the hangers and made new ones to mount the factory locations.





view from the back...




made a flange for the cat and welded together the sections of straight pipe and brought it back to rear section.



used the 90* to finish the under axle section. it was about an inch off so i used a small piece of pipe to fill the gap.





back down on the ground, it is about .5" over to the right but i can bend the hangers over if i get board later.

doesn't rub and has that 1G DSM sound i was looking for and has a stock looking muffer.

finished exhaust from the back...





i didn't have stainless wire at the time so the weld is starting to rust where the hangers went onto the muffler. but all in all not bad for a basically free exhaust.

 

cant beat free

 

looks good for a diy, my last exhaust was a freebee, homemade piece and it worked great until i could afford a nicer one. thumbs up to you