Country Honk, Camaro Revival Part 6 - 1968 Chevy Camaro Adding AC & Exhaust System

Installing the Flowmaster American Thunder system with Series 40 Delta Flow mufflers is simple--take your vehicle and exhaust system to someone like Gene Childers at Muffler Master in Kannapolis, NC. Gene began by marking the exhaust hanger location.

Gene then positioned and aligned the entire Flowmaster system prior to welding or cutting any pipes. This ensures the exhaust system will not rub on any part of the frame, body, or suspension. It's this type of attention to detail that produces years of rattle-free operation. Best of all, the Series 40 Delta Flow mufflers complement the American Thunder system and emit a nice tone when the car is idling or running at a steady rpm.

Our bud Bobby Livengood held the Flowmaster mandrel-bent pipes over the axle while Gene tacked the joints. Once the joints are tacked and the rear part of the system is stabilized, he welded each joint.

It's critical that the turndowns are equally spaced between the bottom of the quarters and the leaf springs...

...Space is at a premium and the Flowmaster mandrel-bent tubing is perfectly shaped to allow adequate clearance, but installation technique and care is essential. With the rear portion finished, we can now move to the front.

While the clearances were tight, Gene patiently maneuvered the header connector bolts into position and tightened them securely into place. Make sure you use high-quality copper exhaust-header collector gaskets instead of the fiber gasket, or there's a good chance you'll be replacing them shortly.

Instead of welding, these stainless connectors were used to secure the header connector pipes to the exhaust pipes just aft of the transmission. If the transmission ever has to be removed, the exhaust can be separated easily and moved out of the way. The connectors conform to the different pipe sizes and form a leakproof seal.

With the entire Flowmaster American Thunder system sorted, Gene finished welding all the connections.

The result is an exhaust system that not only blows all the bad air out, but also emits that distinctive Flowmaster sound when the loud pedal is pushed. The care Gene took installing the system makes the exhaust something you want people to see. You'll find Flowmaster has a large caption under this part number, claiming this system will not fit convertibles. The reason is first-gen convertibles have a different structural support system from the coupes, plus they have an X-brace that increases the rigidity of the body...

...To overcome this, we eliminated the X-brace by having Bobby fabricate the brace you see here. To complete the system, we had Robbie Morrow powdercoat it for durability. It certainly looks better than stock and ultimately, the Flowmaster exhaust has plenty of clearance.