How I Found a Substitute for 1998 Trooper Muffler

{Sorry I wrote this up thinking I could post it with attached figures. Now I see that I can't. I don't think it will be of much use without the figures but here is is anyway}

Many months ago I posted that I found a substitute for the expensive Trooper
muffler. Then I forgot about it. Now I had a request. Well, I'll try to
give a quick overview and some pictures. Then, try to answer any questions.

As I recall, Isuzu wanted many hundreds of bucks for the muffler and over a
hundred for the tailpipe. I couldn't find any aftermarket units. I decided
to see if I could find a cheaper solution. In the end, it cost me about
$60.

For starters, the only thing that needed to be replaced was the muffler.
The pipe up to it and the tail pipe were solid so I kept them.

I fired up my Skill saw with the metal cutting abrasive blade and cut the
muffler out by cutting the pipes before and after the muffler. Then I
cobbled together a cheap muffler, lots of various pipe fittings, and clamps
to make it all go together.

Figure 9 is an overview of how I did it. NOTE!!! THE "ELBOW" PIPE IN THE
PICTURE IS THE WRONG ONE, A 90 DEGREE IS NEEDED TO DO THE JOB. Also note
where I made the cuts. If you cut at other locations, a different set of
pipes may be needed. For the front cut, my saw couldn't get al the way
through the pipe because of interference with the floor as I recall. I had
to use a hacksaw blade to finish the cut.

Figure 1 shows the clamps and hanger that mounts the rear of the muffler.
Note the fiber type hanger. It is mounted at a bit of an angle to reach
from where it attaches to the frame then over to the pipe.

Figure 2 shows the clamps and bracket I made from angle aluminum. It is
needed because the muffler I bought didn't have any bracket on the driver's
side of the muffler like the original one did. Note that the muffler does
not lie flat. It is almost on its side so that the input and output
fittings line up with the pipes.

I bought all the parts from Carquest. Here are the part numbers for the
small pipe fittings starting from left to right in figure 9. I don't have
the muffler number. Sorry.

Adapter 548-510
Adapter 548-510 (Same I guess)
Elbow 548-754 WRONG ONE, Need 90 Degree!!!!

I saved all the receipts but can't find them now.

Wait, I found them. The muffler is 157624 and the correct 90 degree elbow is 548-704.

Still wish I could attach the photos.

I hope this helps.

PeteCal