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To install a custom exhaust on a 1987 Ford Ranger, you must align the 2.5-inch diameter cat-back pipe with the factory flange using a combination of MIG and TIG welding. This project requires a TIG welder, a MIG welder, 2K bed liner, and a 1/8 inch steel skid plate for 1983-2011 Ford Ranger models. This restoration suits owners of 1983-2011 Ford Rangers seeking high-quality sound and durability, while those seeking quick spray-on fixes or standard dealership accessories should skip this.
Who should try the 1987 Ford Ranger V6 Custom Exhaust and Fuel System Restoration
Readers who should try the 1987 Ford Ranger V6 Custom Exhaust and Fuel System Restoration
- Owners of 1983-2011 Ford Rangers should perform this project to improve the sound quality and fitment of the exhaust system.
- Vintage truck restorers should use this method to restore rare factory configurations like dual fuel tanks using New Old Stock (NOS) components.
- DIY fabrication hobbyists should try this to learn specific modification techniques like skid plate notching and custom flange welding.
Readers who should skip the 1987 Ford Ranger V6 Custom Exhaust and Fuel System Restoration
- New truck buyers should skip this and look at new Ford Ranger accessory guides for standard dealership upgrades.
- People seeking quick spray-on fixes should look at quick spray-on rust treatment guides instead of manual fabrication.
Readers who should wait for the 1987 Ford Ranger V6 Custom Exhaust and Fuel System Restoration
- Owners of the truck should wait for the arrival of the rear fuel pump to finish the rear assembly.
- Researchers seeking wiring diagrams should wait for the arrival of the OEM Ford factory service manual.
What to do next about the 1987 Ford Ranger V6 Custom Exhaust and Fuel System Restoration
- Verify the 2.5-inch diameter of the rear catalytic converter and cat-back pipe to ensure proper flow.
- Apply 2K bed liner using a smooth nap roller to achieve a fine-textured, corrosion-resistant finish on the frame.
- Notch the 1/8 inch thick steel skid plate to provide clearance for the tailpipe.
The Challenges of Custom Exhaust Fitment on Vintage Rangers
The 1987 Ford Ranger custom exhaust highlights the “Direct Fit” fallacy, where parts marketed as plug-and-play often fail to align due to variations in pipe diameter and flange positions. Previous owner modifications, such as the crooked welding seen on this truck’s rear catalytic converter, can shift components by as much as 2 inches from the factory position. This displacement requires the installer to perform custom fabrication rather than relying on standard bolt-on components.
The 2.5-inch diameter exhaust piping creates specific clearance requirements that may not match modern “direct fit” offerings. Because the rear catalytic converter is positioned further back than originally intended, the cat-back section is pushed toward the rear of the vehicle. This situation forces the installer to choose between cutting off the catalytic converter or welding a new flange to the pipe. Choosing to weld a new flange ensures a proper seal and maintains the intended exhaust flow.
Modifying Components for Perfect Alignment
The 2.5-inch diameter cat-back and catalytic converters are the core components of this exhaust upgrade. Modification involves ensuring the transition between the catalytic converter and the tailpipe is seamless and structurally sound. Sarah -n- Tuned chose to use a combination of MIG and TIG welding to secure the new sections in place.
The fabrication process utilizes a MIG welder for heavy-duty structural joints and a TIG welder for precision work. TIG welding provides high-quality, clean welds that are essential for a professional-grade finish on the exhaust. The welder must have access to both machines to handle the different angles and positions required for the rear assembly.
Restoring the Dual Fuel Tank Configuration
The dual fuel tank system on the 1987 Ford Ranger relies on a switching valve to move fuel between the front and rear reservoirs. This specific truck had the switching valve and its associated wiring removed, a process known as electrical deletion. Restoring this function requires identifying whether the circuit was intentionally removed or simply disconnected.
The 1987 Ford Ranger fuel system relies heavily on New Old Stock (NOS) parts for successful restoration. Because modern “cannibalized” parts often fail to fit rare factory configurations, sourcing genuine Ford Motorcraft components is often the only way to ensure correct fitment. Sarah -n- Tuned notes that finding these rare, obscure parts is a necessary niche for high-quality restoration.
The fuel switching valve requires a functional ground and power to operate correctly. If the valve does not respond when the switch is flipped, the owner should check the fuse box for the diesel/switching circuit. A lack of a fuse or a broken ground wire often explains why these systems fail to function.
The dual fuel tank system is a time capsule.
Achieving a Corrosion-Resistant Frame with 2K Bed Liner
The 2K bed liner provides a durable, textured, and corrosion-resistant finish to the truck’s frame. Unlike standard paints, this coating uses a two-component chemistry to create a bond that resists flaking and environmental damage. The application process involves pre-treating the frame to ensure the coating adheres to the metal.
What is 2K bed liner?
2K bed liner is a two-component coating that provides a durable, textured, and corrosion-resistant finish. The coating requires mixing a base and a hardener before application to trigger a chemical bond. This process creates a finish that is significantly more resilient than standard spray paint.
The application technique uses a smooth nap roller to achieve a semi-textury finish. By working the product until it is even, the installer can avoid visible roller marks while maintaining a fine texture. This creates a surface that protects the frame from the elements without becoming overly thick or heavy.
Ensuring Clearance and Preventing Vibration
The 1/8 inch steel skid plate must be modified to accommodate the path of the custom tailpipe. Without proper clearance, the exhaust may vibrate against the plate, leading to noise or structural damage to the exhaust pipe. The solution involves notching the corner of the skid plate to create a specific clearance path.
Notching the 1/8 inch steel plate ensures the exhaust does not vibrate against or hit the skid plate. The installer should use a body saw designed for sheet metal to make the cut. This modification is essential because the 2.5-inch exhaust is only listed for 89-94 Ranger fitment, and the skid plate may interfere with the path of the tailpipe.
How Bolt-on Cat-back Exhausts and Standard Spray Paint Differ
Comparing these two common modifications highlights the difference between specialized fabrication and general-purpose coatings.
- Bolt-on cat-back exhaust
- May require custom welding or modification if the factory pipe diameters or flange positions differ from the advertised specs.
- Standard spray paint
- Lacks the durable, textured, and corrosion-resistant properties of a 2K bed liner.
The ‘Fake’ Removability of Exhaust Clamps
Many DIYers believe exhaust clamps offer easy removal, but on 2.5-inch diameter piping, these clamps often crimp the pipe, creating a permanent mechanical bond. Because the clamps crimp the pipe to create a seal, they are essentially permanent once installed. Using tack welds allows for a more precise fit while maintaining the ability to adjust the assembly before the final weld.
Sarah -n- Tuned has not specified costs or diagrams for the 1987 Ford Ranger
- Sarah -n- Tuned has not specified the cost of the custom exhaust; check local fabrication shops for current welding and fabrication rates.
- Sarah -n- Tuned has not specified the price of the 2K bed liner; compare costs of various 2K coatings from automotive suppliers.
- Sarah -n- Tuned has not provided the specific wiring diagram for the switching valve; consult a Ford factory service manual for the 1987 Ranger.
Worked Example: Restoration of a 1987 Ranger
Suppose Mark is restoring a 1987 Ford Ranger and wants a custom exhaust and rust-proof frame. Mark applies 2K bed liner to a pre-treated frame using a smooth nap roller and orders a 2.5-inch diameter cat-back. After finding that the flange doesn’t line up, he welds a new flange to the pipe and notches his 1/8 inch steel skid plate to provide clearance for the tailpipe.
The truck gains a durable, textured frame and a custom-fitted exhaust that sounds much better without leaks. If Mark had found a Ranger-specific fuel pump instead of a Bronco II variant, he would have avoided the hour and a half of failed swapping and instead moved straight to installation.
Frequently Asked Questions
Does the 1987 Ford Ranger exhaust work on all models?
The 1987 Ford Ranger exhaust works on most models from 1983 to 2011, although specific fitment may vary based on previous modifications. The source notes that while 89-94 is a common fitment, most systems are similar across the 83-2011 range.
How much does a custom exhaust for a Ford Ranger cost?
Sarah -n- Tuned has not specified the cost of the custom exhaust. You should check with local fabrication shops to determine current pricing for custom welding and fabrication.
Is it safe to drive the truck in winter with road salt after the frame is coated?
It is not recommended to drive this truck in the winter with road salt because it is an antique and should be treated as a time capsule. The focus of the restoration is preservation over heavy-duty utility.
How do I fix a Ford Ranger dual fuel tank switching valve?
To fix a Ford Ranger dual fuel tank switching valve, you must check the fuse box for a diesel/switching circuit and verify if the system has been electrically deleted. If the circuit is active, ensure the switching valve has a proper ground and power supply.
The final result of this restoration provides a vehicle that preserves its history while improving its functionality. The combination of 2K bed liner and custom welding ensures the truck lasts for future generations.
Reported from This Sounds WAY better! // '87 Ranger V6 Custom Exhaust, published by Sarah -n- Tuned.