Hello,

I figured I would start a new thread for my project as I did not find one for my truck. Just going to post a few photos and keep the project moving. Definitely could use some assistance with the following:

1. Custom Exhaust Build (2.5" Straight pipe with Cat and muffler)
   1. Has to be quiet
   2. I can and will be welding it myself, so purchasing the correct muffler is my biggest concern
2. Missing under dash panel
   1. I have searched everywhere and cannot find the panel that covers the fuse box near the drivers left knee
3. Paint
   1. Where is the best place to find factory blue paint

Thank you in advance for the assistance!!!!! Hope you enjoy the project as much as I am going to!

 

Looks like a good project, 2.3l 4x4 regular cab are not all that common

Looks like Ford Regatta Blue inside and Ford Medium Regatta Blue Poly outside, may be Ford Bright Regatta Blue Poly
Have a look here: https://www.uniquecarsandparts.com.a..._ford_usa_1988


Parts for an 1988 will, of course, be hard to come by

 

Awesome! Thank you for the link!

I was able to locate a CAT on Amazon (linked below). Decided to switch gears and try and return it as close to stock as I can. I am going to weld straight pipe from the down-pipe to the CAT and reuse the factory setup (pictures). It doesn't appear to have any leaks outside of the botched CAT delete job done by the previous owner. I plan on cleaning it up and ceramic coating it for longevity.


Thoughts?

 

Found this as well for those that are looking to update their exhaust.

Walker Tail Pipe (Currently $22) -

 

What no tin cans to fix holes in the pipe, lol

Yes, looks like quite the high school exhaust repair

 

Alright, here is what I have completed so far:

1. Replaced the Reverse Synchro Sleeve
2. While assembling the transmission I found a hairline crack in the Reverse Synchro Ring
I was able to locate the part after 2 days of calling around and searching. I was able to have it overnighted. Found the part here - https://www.finditparts.com
3. Finally rebuilt the transmission
4. Cleaned the drivetrain with purple power
5. Reinstalled drivetrain
6. Welded the exhaust and reinstalled with cat
7. power washed the carpet and let it dry before reinstalling
8. Interior reassembled
9. Tested electrical and found a bad dome light and the aftermarket stereo would not power on
8. Checked and bled the brakes

So far he has been a good project truck. Have a few more things to iron out and it will be g2g.

To be completed:

1. Headliner
2. Door panels
3. Dash
4. Locate a factory stereo
5. Suspension renewal
6. Paint...

 

Good stuff

 

Looks good getting ready to start on a 1988 xtl, First thing I want to do is split the exhaust into dual on the 2.3. any ideas on the split 1/3, 2/4 or 1/2, 3/4.

 

Google: scavenging exhaust how to

That's where you start when designing header pipes or you will LOSE POWER for sure
the pipe size needs to be small enough to create a Velocity that will create a lower pressure in the smaller pipe when it goes into the larger pipe, the collector

Popular MYTH about gasoline engines needing back pressure comes from people that put on "free flow" systems with larger pipe headers, and then found out they LOST POWER
And then came to the wrong conclusion, lol
Factory exhaust manifolds are "tuned" to get scavenged power, and they lost that when they used "untuned" headers