Here's my take on the situation.

First of all, get yourself a new pair of heater boxes.  The heater boxes (or
exchangers) bolt directly onto the heads.  E-mail Stan Wilder. I think he
has a goiod used pair.   Next, order an S&S header and muffler like this
one.

http://www.gexintl.com/48s&sheaders4.htm

Bolt this onto the heater boxes and you're done.  Easy, simple, cheap, and
you'll improve your horsepower.

Other things to check out are the engine tin, and the metal tubes that
complete the heating system.  If the exhaust has been truly dismantled and
screwed around, these may be gone.  You need them.  there are two tubes that
come off of the heater boxes.  One from each end.  They brong cool air in
from the alternator blower, and take warm air away, out to the heat control
valves.  As far as engine tin, you should at the very least have the two
bottom pieces that cover the pushrod tubes.

Don't worry about putting a cat back in.  If it didn't have one, don't add
one.

The alternative is rebuilding the system as it came from the factory, which
would be really expensive unless you can score the whole system used.  The
crossover pipe alone is in the 300 dollar range if you can even find one.

Only consideration with this setup is what to do with the EGR.  I don't have
one, so I'm not to sure, but I think you could likely get rid of it.  Not my
area of expertise.  (o2 sensors though, ....just ask me!)

I'm a big fan of the S&S header.  Extra power, nice sound, and very simple.
If you can afford it, get it professionally ceramic coated before you put it
on, it'll last much longer.

You can handle the job on your own.  If you have any questions, just send me
an e-mail,

Greg
82 Westy.

"Russell, William" wrote:

> There is just no end to the stuff that I want to fix on my Westy.  The
> exhaust system is horrible.  Apparently, a PO was in Mexico, suffered
> problems, and had a mechanic bastardize the system any way he could.
> I'd like to consider replacing the whole system.  I'd like to go high
> quality and original parts if at all possible.  I guess I need whatever
> the bits coming off the engine are (help!), the heat exchangers, the
> crossover, muffler, tailpipe, et cetera.  I have a few questions:
>
> Any recommendations on who to buy it all from?  Past experiences?
>
> I currently have no catalytic converter.  I think my Westy was built for
> Canada.  Can I add one now?  Should I?  I'd like to be environmentally
> responsible if at all possible.
>
> Can I do this myself?  I don't have a welding torch.  I'm pretty good
> with problem solving and tools but I'm new to working on vehicles.  I
> have a brother-in-law who's a mechanic that I might be able to get to
> help if I need him.
>
> Anything else I should take into account?
>
> Thanks,
>
> \/\/i!!y
>
> 1980 Westy "Jazzy"