I wanted to share my DIY Solution for a replacement catless Y-pipe for my 2000 4.0l Ranger. for context, as far as I'm aware, there are no manufacturers who reproduce an OEM-style Y Pipe without a pair of catalytic converters included for 4.0l trucks of this era. The only replacements I know of retail for about $400. Since my truck already has cats further back, and never came with an extra pair up front, I decided to try and fabricate a pipe from off the shelf parts.

I wound up purchasing this AP Exhaust 93102 pipe intended for a 90s Explorer(?) for $100. it has the same manifold flanges and I believe the same flange for the rest of the OEM Ranger exhaust as well, though mine was rotted apart and I'll have to fab a new one so I can't say for certain. From there I bought an off the shelf 35° (?) angle exhaust sleeve from Napa with a slightly larger ID than the AP pipe's OD. Then it was just a matter of cutting the driver's side of the AP pipe at an arbitrary distance into the curve, then attaching both pipes to the manifold, marking and cutting the angle sleeve, and then fitting it up and tacking it before taking it down and welding it solid. This might put your main exhaust flange at a different rotational angle to the rest of the exhaust, which can be remedied by cutting the rest of the exhaust further down and re-welding at the right angle. For my replacement flange I'm using 1/4" or 3/8" plate steel which I'll drill holes in with a hole saw and flatten out with an angle grinder.

If you don't have a welder something similar is probably possible with aftermarket exhaust sleeves and U clamps, but welding is the best solution in my opinion. Also note that most of the aftermarket pipes you'll find are galvanized, so wear a good respirator and weld outside if you decide to go that route.

Here's the final result, painted over with high heat paint to help protect the welds from rust. Hopefully this will help someone down the line, since I had to take a shot in the dark with this project.