County Needs New Exhaust

[tc_s1]

1987 110's exhaust has about had it. For the past few years I've tried different things (patching, splicing with flex, etc.) but it never seems to last and on a 300km trip today the wife's feet started getting very hot, then of course with the window down I could hear a bit more of the turbo whine than normal, so I knew I'd cracked it again. Seems the old pipe suffers from metal fatigue. Not even rough riding today, 90% on pavement with some gravel hardpack, so it's time I fix it more permanently.

I'm thinking time to replace the exhaust with new. What option(s) has anyone tried short of building some custom exhaust?

Ideally I'd like it to stand up better to the 4bd1 rattle/turbo heat, not crack for at least a few years at a go and perhaps give it a bit more clearance from the tyre on tight radius turn (rerouted it slightly a few years ago when patching to help this with a bit more clearance in the event of a tight turn and jolting maneuver in concert). Am also considering some shielding between the pipe and the pan so SWMBO's toes don't light on fire in summertime on long drives.

Have thought about expanding the diameter by perhaps 30% or so as well (to maybe 3"), as I believe that will help with diesels in general, perhaps with a snorkel with better air intake as well (tbd).

Has anyone done similar work? What have you done, tried, modified? What works and what doesn't/didn't? I've seen some who have suggested getting the military perentie replacement exhaust and fitting/modifying that as a starting point, but not sure. Input and guidance appreciated. Thank you in advance.

[JDNSW]

Interesting - I am on my third muffler in almost 700,000km, but the rest of the system is, as far as I can remember, original! Certainly it is several hundred thousand kilometres since I have done anything to the exhaust except replace the rubber on the rear suspension point during my trip to Perth and back in 2018.

I would ask the question - is the brace between the engine pipe and the starter mounting bolt missing? This would be likely to cause the sort of problem you seem to be having, as would, of course, bad engine mounts.

[tc_s1]

Interesting - I am on my third muffler in almost 700,000km, but the rest of the system is, as far as I can remember, original! Certainly it is several hundred thousand kilometres since I have done anything to the exhaust except replace the rubber on the rear suspension point during my trip to Perth and back in 2018.

I would ask the question - is the brace between the engine pipe and the starter mounting bolt missing? This would be likely to cause the sort of problem you seem to be having, as would, of course, bad engine mounts.Interesting indeed. It doesn't appear that anything is missing and it is (other than the added flex section) identical to how it was when I bought it. I had assumed due to having to weld it several times that the exhaust was simply fatigued after nearly 35 years, and the motor mounts were taken care of a few years ago along with a rebuild, but if you're going strong without any issues it leaves me scratching my head.

[JDNSW]

See PM.

[Vern]

Just get an exhaust shop to make one. I made my own, 3" mandrel bend and dump pipe. Had the flexy joiner in the dump pipe, worked well.
I believe though that klr make an off the shelf exhaust now thats pretty good.

[JDNSW]

174328
This shows the position of the stay, taken behind the LH front wheel.

This issue is not restricted to Landrovers - many years ago (1973) I rented a truck to help my parents move here from Sydney. I think it was a F-350. On the return, the exhaust pipe broke, and I managed to find sufficient wire from the foot of a strainer post in a nearby fence to hold it in place and reduce the noise. While under it doing this, I noted a disconnected stay in a similar position!

[tc_s1]

Final disposition on this in case it helps anyone. I ended up following the great advice offered here and after more review with an exhaust specialist here, he pointed out that there was a weakness in the downturn from the turbo that was causing the exhaust to split due to repeated stress. We welded a long 'finger' down the pipe, tying it as added support for the angle and there hasn't yet been any repeat. Admittedly I've not been driving the truck as frequently lately but it has performed well on weekend trips with some offroad bits, on 5+ hour higher speed interstate jaunts and no signs of fatigue have returned. THANK YOU to everyone for your help and support as I worked to sort this.