DIY Transfer case exhaust crossover advice/experience

2015 DCLB 4x4 4.0. For the exhaust crossover pipe that hangs below the frame crossmember at the transfer case, has anyone had luck making that replacement pipe themselves to tuck it above the crossmember to clear skids? There are a few different solutions, but the one i've linked below seems like a great option to me.

From searching the forums, it sounds like the general consensus for the pipe size is 60mm stainless. Ish 2 3/8" OD.

I see past posts where guys get the work done for $170-$200 at a local shop.

I like the way qnyla had it done on post #79 here, still utilizes the heat shields, and just raises it up enough to clear. Very simple and only 2 bends. : https://www.tacomaworld.com/threads/exhaust-re-routing-pictures.237030/page-4
Here are his pictures:




As a quick feasibility assessment, I'm looking at the 16 Ton bender from HF for 220 minus coupons, which looks like it has a 2" and 2.5" die, and I can get a 4ft piece of 2" schedule 40, 304 stainless for $125 locally, which should be close enough to what seems to be the OEM 60mm, for a butt weld. I might try and cut the existing section out and splice a shorter section of pipe on there for cheaper if it looks like I can reuse it.

My problem is that I enjoy NOT paying people to do something that I can learn to do myself. Especially if it means I can acquire more tools. I may not have saved a ton of money on automotive work over the years, but I've got a lot of tools out of it.

 

I've done similar crossover reroutes on a 3rd gen just utilizing some exhaust tube and mandrel bent elbows from Summit racing. IIRC I just bought a couple of 45's and 90's and pieced it together in-place then removed, fully welded and wrapped it with header wrap to control heat since it's closer to the T-Case than it was originally. Can be done in a couple of hours pretty easily with a sawzall, grinder, and welder.

 

Great idea. I completely forgot you could buy pre-bent sections. I see they have some 30 and 45 degree sections that look like they might be close to these pictures. That might make it even more feasible to re-use the old section.

 

That's some seriously heavy material for this task. the OD of that sch 40 will be a pretty close match to the stock tubing but the ID will be significantly reduced. It might not be much of an issue for you but for the cost of materials, I'd avoid it.

 

Yeah, they have good prices for short sections of a lot of stuff, they normally ship things but they have a warehouse 30 min from the house so pickup makes things really competitive. Metals4uonline.com I’ve gotten their value packs on a handful of occasions for angle. Anything in 4 ft lengths is great. If I can re use a portion of the old one, I might be able to get away with a shorter length.