Adding XR7-G exhaust cut-outs to a 1967 or 1968 Mercury Cougar

There’s one detail of the 1967 Cougar that always bothered me — the way the exhaust sits under the rear valance.

Originally, I believe the Cougar had turn-down exhaust tips that were somewhat hidden, but through the years almost everyone has run the exhaust under the valance, both to keep fumes out of the car and to give it more of a muscle car style.

However, in 1968, the XR7-G package boasted exhaust cut-outs with chrome trim rings, which to me, makes the back end of the car look much classier. Since I was undertaking body work to prep my car for paint, I decided to retrofit the XR7-G trim rings and exhaust tips onto my 1967 standard.

I ordered the trim from West Coast Classic Cougar. While it seems like a high quality reproduction part, all repro parts have their quirks. The odd thing I found about these trim rings is that one mounting peg is a different size. With pegs facing up, the right peg is a size smaller than the center and left pegs. This really doesn’t matter except that the spring nuts supplied with the rings are all the same size. They fit tightly on the center and left pegs, but fall right off the right peg. You will have to source a smaller size spring nut to mount them.

One good part about these trim rings is that they are symmetrical, so you can easily flip them over to trace the pattern onto your valance.

Step one was to remove the rear bumper guards and brackets. Not all Cougars had the bumper guard option, but if yours had them, and you are removing them, don’t throw them away. Each bumper guard has a core value of $50 and the brackets trade for about $100 a pair.

I got varying measurements from XR7-G owners as to how far apart the cut-outs should be spaced. I found my exhaust pipes lined up right under the top mounting holes for the bumper guards, so I used those to mark the centerline for my cutouts. I’m not trying to pass off my car as an XR7-G, so I would much rather have good exhaust alignment than perfect factory specifications. If you’re measuring from the bottom edge of the valance, on mine the outside edge cuts were exactly 8″ off the end-curves of the valance.

I could have probably cut the entire shape out with a dremel, but on the Classic Cougar Community forum, a member suggested using aviation tin snips to quickly do the bulk of the cutting and then just clean up the edges with a dremel. I decided to give that a shot — plus it gave me an excuse to buy some nice tin snips.

The only downside to the tin snips was the bend it puts in the lower portion of the valance, but it was easily tapped straight with a hammer and a dolly. I finished cutting and cleaned the edges up with a dremel.

Drilling the mounting holes precisely enough to get the bottom edges to line up perfectly straight was the trickiest part. Using good metal bits and stepping up the hole sizes made it much easier. In the end, I had to oversize a few holes to give the trim some adjustability.

My exhaust hangers were adjusted all the way down to get the pipes under my rear valance, so it was easy enough to raise them up to move the exhaust tips into the new cut-outs. However, it wouldn’t be a DIY project without an unexpected challenge. I didn’t notice that the backside of one hanger bolt had two nuts on it, and I twisted off the head trying to tighten it back up.

Thankfully I had a replacement nut and bolt rolling around in my toolbox, so it only caused a short delay.

The old rusty exhaust tips already look better poking through the new cut-outs. It will look really great when I have the larger, shinier XR7-G tips welded onto the system.

Once I had proof of concept and good measurements, I ran through the entire process again on the reproduction rear valance that I’m prepping to install before I paint the car.

I think I may toss the flat nuts and use speed nuts to install the trim rings, so that they are easier to unscrew if I want to repeatedly install and remove them while I continue doing body work and changing things on the car.

So now that I have the XR7-G exhaust trim, the real question is whether or not I should add the XR7-G hood scoop!

Does your boat have eyebrows?

I’ve never really understood having eyebrow rails on boats. Does it make them more expressive? Ours just seemed to catch dirt then get broken when people slid off the cabin top and caught their feet on them.

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Within weeks of buying Gimme Shelter, a section of our starboard eyebrow rail had snapped off. Then another and another. By the time we rang in 2017, we were missing several sections of the trim on both sides of the boat.

Since O’day has been out of business for decades, there were no readily available replacement eyebrow rails. I had a discolored strip of gel coat with exposed screws sticking out that needed to be addressed.

From the beginning I knew I didn’t want to use screws to install the replacement. I looked into buying teak boards and cutting my own, but it was expensive, and I wasn’t sure how it would turn out. I looked into PlasDeck and NuTeak to see if they could replicate the originals for me, but they said they would have to make the rails wider and the plastic would require screws because an adhesive wouldn’t stick to it. I even thought about skipping the teak altogether and just putting a blue pinstripe on the cabin to cover up the stain.

It was by pure coincidence that the local boaters resale shop happened to have a set of never-installed eyebrow rails for a Catalina 34 for $99. (They’re $203 from CatalinaDirect.com.) The O’day rails were 14’4″ while the Catalina rails are only 14′, but they were pretty similar.

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I removed all the screws, filled the holes with epoxy, and stuck the new eyebrow rails on with 3M emblem adhesive — the same stuff I used to replace the fixed ports.

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The entire project was painless, which was such a relief after the nightmare of our heat exchanger replacement.

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The only downside was that the new eyebrow rails made our hand rails and toe rails look terrible. We spent the entire next day sanding them down and oiling them to make them match.

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Gimme Shelter is looking great.