Finally fixed exhaust leaks on the JKU, I had the manifolds and catalytic converter installed before my knee surgery and haven't driven it much since. When I finally got around to driving it the exhaust smell was too much; thought I had cracked exhaust manifold but on closer inspection the aftermarket exhaust manifolds and Magnaflow catalytic converter flanges did not match up. Since too much time has passed since I paid to have it installed, I was relieved no manifold cracks, but was pissed and disappointed that they didn't notify me or at least make an attempt to fix the misalignment.
both sides looked like this, bottomed out on one side, leaking like a bastard on the other:
Loosened all the clamps on the cats but no twisting or prying was making them line up. Thought about using pipe flange donut gaskets but don't know how to measure to get the right size for a proper seal. After a few words not safe for neighbors, I remembered I had exhaust wrap left from the header experiment, put a strip of around the exhaust manifold mating flange, also rotated the flanges on the cats (they had a slight bend) leaks sealed.
Replaced the crap clamps they used with some I saved from another exhaust; don't throw reusable parts away, they've sat on my spare parts shelf for at least 6 years lol but saved the day and $$ today.
I could have taken it to a muffler shop, paid to have them cut the pipes, and get everything fixed but calling around they wanted $125+ per hour plus materials... nahh
FYI, removing the passenger side tire and inner liner made it much easier to access the manifold/cat flange, trying to do it from underneath works but you can't tell if it's seated properly.
Tip for those needing to do the same: Trick I learned years ago from my brother-in-law's dad, use a shop vac, put the hose on the exhaust of the vac to blow out, put the other end of the hose in the tail pipe and using soapy water spray everywhere you think there might be a leak. There is enough pressure from the vacuum to create bubbles where the leaks are, and you don't have to work on a hot exhaust.
I intended to take more pics but after the 1st one I got pissed at the shitty work I paid for, got focused on getting this shit done and well, you get 1 pic. It's a janky repair but got the job done.