5" Exhaust Questions

[WadePatton]

Okay I couldn't live with the straight 5". Couldn't get what I wanted, and couldn't stand another minute in the big city, so I wound up with a 10" muffler. Don't have the number handy. Peeked at it before I bought it and DID NOT see the baffle. The baffle is a perforated screen of metal folded so that a cross slit is left in the middle. Paul and I beat the crap out of that baffle and opened the "+" up a little bit. Then we fitted it on there.



Just a little bit too tight. The muffler is banging the rear cross and the tail pipe is agin the spare.



And the muffler is too quiet. Don't get me wrong it sounds GOOD. But when I get a chance I'm going to pull the muffler (yeah, band clamps) and whoop on the baffle some more and put a bigass dent in it for clearance. Until then its going to be rubber and stayties. Muff was $64 at Tennessee Filter.



So I recommend a 9x51 muffler or just a resonator. And we did a bit of welding for two clamp/hanger deals. I'll get photos after I add the chrome tip! (Camera was in the truck up on the rack today)

 

[satmike]

I went the quiet route. I took the 2' muffler that came with the system, cut the baffle out with a saws-all and mounted it so the back it was just forward of the carrier bearing then just behind that I mounted a Donaldson m090535 (51"x9" no baffle) muffler. Put it all together with band clamps for easy adjusting. Still working on making a few more hangers with the clamps that came with the kit and waiting for the stainless tip. They said it should be here this week. I haven't towed with it yet but so far no drone and as quiet or better than the stock system. So far I'm very happy. I wanted it to breath and still keep it quiet. Next project sound deadening

Later Mike .

 

[fishjack1]

Several questions about 5" Exhaust

Ordered my 5" big-exhaust and it should be here this Friday. I have a couple of questions that I would appreciate some help with:



Should I pay to have it installed or do it myself? I have done just about everything else to my truck myself and have all the tools necessary just don't want to get in a bind crawling under the truck with no lift.



Is there a gasket that needs to be replaced at the turbo where the down pipe attaches?



I want to use the S. S. band clamps. How many will I need and are the mounts that you must use welded to the clamps that big exhaust sends?



Sorry about so many questions but I am excited and if it does not arrive till Friday my exhaust shop won't be able to install it till Monday. I will not be able to sit and look at it all weekend in the box.

 

[WadePatton]

Depends on what they charge you. My exhaust man welded two custom clamps and mounted the muffler for $20--'cause "you done all the work" he said.



At the very least take it out and spend a few minutes beating the ends back straight after UPS bangs it around. I used a big hammer (2#) and a 4WD hub socket as a dolly. Could have used something better (bigger).



I'd recommend doing just what I did. Being 2WD, I parked mine over a depression in the yard for more room and hacked out the old and jammed in the new. You may have to shorten it--don't cut off a flared end! Hacking out the old and pre-fitting the new (de-dinging) takes most of the time. Then Monday the muff shop can fix up anything if needed.



No new gasket at the flange. One 4" band clamp and three 5" band clamps. They are $10-15 each--but are worth it. My system has already been apart once and will be once more-at least. I'm hunting that perfect sound.



Tool list:

9/16 wrench and socket for band clamps. 9/16 for 5" clamps. 13mm for flange nuts. Sawzall or hacksaw or die grinder with cut-off disc. Strong grubby fingers for mount rubbers. Dirty rag for wiping that SE grin off your face when you hear it.



Hanger/Clamps-they're all welded except the one that goes to the transmission. You can weld this directly to the pipe, or do as I and another member here did and weld it to a 5" clamp so that it is removable too.



I'll try to get some photos up tomorrow after I move some tractors around.

 

[WadePatton]

Originally posted by satmike

I went the quiet route. I took the 2' muffler that came with the system, cut the baffle out with a saws-all and mounted it so the back it was just forward of the carrier bearing then just behind that I mounted a Donaldson m090535 (51"x9" no baffle) muffler. I wanted it to breath and still keep it quiet. Next project sound deadening

Later Mike .

That has to be almost silent! The Donaldson M100465 is a 10x51 with one stout baffle in it. It's just too quiet with it on there. I'm going to pull it and try to die grind the baffle out. I jammed a exhaust hanger dougnut between the muffler and the frame today. Secured it with fence wire-no more rattle.

 

[fishjack1]

Wade,



Thanks for the info.



I should have mentioned that I ordered mine w/o a muffler. Does that change anything? I am going to try that first and if it is too much will install a muffler later.



Will I still need 3 fives and 1 four inch band clamps?



Thanks,

 

[bmoeller]

FishJack-



I bought the muffless also. For the most part it is OK on sound level, but hitting about 21-2200 rpms or O/D gives me a headache. Sounds awesome aside from that (espeecially driving alongside of a concrete barrier on a bridge . I am planning on getting a resonator (Iowa 80 had them on back order, so I didn't have one when Installed the system) to take the edge off.



If you don't get a muffler, 1- 4" and 3- 5" clamps are all you need. I bought 4- 5" so I could install the resonator.

 

[WadePatton]

Originally posted by fishjack1

Wade,



Thanks for the info.



I should have mentioned that I ordered mine w/o a muffler. Does that change anything? I am going to try that first and if it is too much will install a muffler later.



Will I still need 3 fives and 1 four inch band clamps?



Thanks,

There is a short section of double flared pipe that takes the place of a muffler in the kit. So the # of clamps is the same-muff or no muff.



On MY truck running without a muffler was just nasty at 2150. There was a really sharp/loud BRRRRRRAAAAAAAAAP at that RPM when going throught the box and FORGET about running 77-80MPH. Good news is that there is absolutely NO DRONE with a muffler in place. At least not with a M100465 or with a modified M100465 (semi-gutted and beaten to fit). I had a bit of drone with a resonator only factory setup. None whatsoever now.



THE muffler is M090535 (Donaldson). I'll get one after the injectors and air horns.



A resonator might be enough. That BRAP is wicked and pissy.



So a die grinder, torch, pnuematic chisel, sawsall, and MORE were used to cut that stupid 465 baffle out today. I got the turbo-through-the-tailpipe sound again. I wouldn't put one of those on my mom's truck.



All deaf and covered in soot--life is good.



[edit]

The perfect sound is JEST a little bit louder than what I have now. And if you have a pipe that is just a bit snug--like tailpipe to muff--slap some grease on that baby. I did and it worked wonders. KY ain't just for Kentuckians you know.

[edit 2]

PHOTOS tomorrow I PROMISE! and the spare tire is a BEE-OTCH. Take it off until you get done and then SEEF you can squeeze it back up there.

 

[DBCooper]

Fishjack, the only other thing you may need is a pair of ear plugs when you're done!

I found some nice band clamps at a big rig shop here in town for about $6. 50, so shop around. Also, a little wd40 on the rubber hanger thingamajigs helps a lot.

I was the other guy that welded the trans mount hanger to an extra 5" clamp. Works real nice. You'll have an extra couple of them since you're going with bands. Have fun and don't grin too much.

 

[fishjack1]

Wade,

Thanks for the advise and wish me luck - the system will be here tomorrow via UPS and I guess I will go at it on my own.



I like the sound of a loud diesel but I may end up getting a muffler. Will post and let you know how it goes.



Until then - happy smokin!!!

JACK

 

[fishjack1]

Installed the system with some help from a muffler shop. Yep I chickened out. I also ended up not using the band clamps. The old timer at the muffler shop told me that the pipes might twist with the band clamps so we used the ones that came in the kit and he welded them as well - overkill I'm sure.



WOW! It is loud, will have to get the reaction from the neighbors b4 I decide on a muffler. I like it loud and I may just have to idle around the house. Thanks for all the advise but It was nice having him help and having the truck on a lift. He cut the old system off with a torch in about 3 min. We had the new one on in about 30 min. Needless to say this was not his first exhaust system install. But he said that it was by far the biggest. He called several friends over to look at the system after we were finished. Only charged me $50 and I was more than happy to pay that.



The only thing I don't like it that the tail pipe is closer to my rear tire than the stock system was. Had to push the tail pipe forward to allow for clearance for my spare. Thanks again for all the responses.



Jack

 

[WadePatton]

5" photos

Who's your Daddy!

 

[WadePatton]

Here's one way to do the transmission mount. Stick bar in from front and then weld to clamp.

 

[WadePatton]

Why not to use a 10" muffler. I hammered in some clearance. The wire is holding an exhaust doughnut I used before the hammer mod.

 

[WadePatton]

Custom extended hanger.

 

[WadePatton]

Spare clearance on mine isn't proper. I need to shorten the system some more. Waiting on rack.



Let a 6. 9 driver drive it tonight so I could hear from the roadside. Too quiet. Will cut some more @#$% baffing out of muff tomorrow. He said it was a little peppier than his truck--I let him have it on 2x4 and told him to keep the boost under 10#! She was cold.

 

[Archive]

Wade. . does that come straight out the side... or at an angle. . can really tell from the pics... Thanks

Bryan

 

[WadePatton]

Pretty square to the body. Looks just about like a 12v exhaust. I'm going to cut a chrome tip and try to restore that "factory" look albeit bigger.



MORE photos then.



AND took the torch to the innards of that awful m100465 again and completely removed the first baffle. Now she's sounding like somebody again! Got the tailpipe a little further forward too, didn't try the spare again, but it should fit fine. You know those band clamps stretch a bit after you've had 'em off and on a dozen times.

 

[fishjack1]

Well I've gotten used to the new (awsome) sound of my truck with the straight 5" system. I now actually crack my passenger side window a bit on the interstate at the 2250 (drone) range esp by guard rails etc. just to hear it purr or should I say ROAR.....



As long as I don't get pulled over for noise violations I guess I will avoid a muffler/resonator install.



Anyone else waiting on the 5" angle cut S. S. exhaust tip from BigExhaust? - it is on backorder. Anyone know of another source for a S. S. angle cut tip for the 5" system?



Thanks

 

[WadePatton]

I have a few 48" pieces of used 5" CHROME that I got CHEAP at a truck repair place. I'm going to angle cut some of that and make a tip. Just hain't done it yet. I'm going to have about $5 in the tip. Five for the pipe, I cut it and I doubt the muff guy will charge to weld it on.