2nd Gen Non-Engine/Transmission Anyone tried this exhaust modification?

[keimmmo]

I have been reading about lots of different ways to modify the exhaust on our trucks, but I have not seen this one. Years ago it was popular on heavy trucks with gasoline motors and sometimes a hot rod to run gutted mufflers. The performance was better than glass packs. The noise was reasonable... about like a Flowmaster.



The way it was done was to cut the muffler in half in the middle. Then torch out all the pipes inside except for a stub at the inlet and outlet. The baffles were left in place to support the inlet/outlet tubes and also served as sound deadening chambers. Then weld the muffler back together.



If you are able to weld, this modification costs only the price of your welding supplies. That is attractive compared to the price of a new muffler! BUT, how does it sound on a diesel? Also, how would it affect the warranty since it is still the original muffler?



Steve

________________

2001. 5 SLT Laramie QC 4X4 Loaded but stock

1992 Extended cab 4X4 with 300,000 miles!

 

[Got Smoke?]

Why not just remove the muffler?



I did 20,000+ miles ago, and I still love it! Oo.

 

[emjay]

Hey, got smoke, I was thinking about doing that. How much louder is it? Do you hear a drone in the cab?

 

[JR2]

The muffler on my Diesel Dynamics 4" system is not much more than a bigger piece of pipe. It is about 8 inchs in Dia and has a four inch pipe that is slotted running all the way through it. I think it is more of an expansion chamber and less of a muffler... .



It sounds great. .

 

[keimmmo]

If you want all out performance, an upgrade to a 4" system would be the way to go. Or, if you WANT noise, a straight pipe is the answer. However, I do not plan to make any modifications beyond freeing up the inlet and exhaust a little. (No boxes or injectors. ) The factory 3" system should be fine for my level of performance.



However, noise IS an issue for me! Also, keeping my warranty in effect IS an issue. I am looking for a way to keep the noise down while getting rid of some back pressure AND still keeping my warranty good. This strikes me as a viable option. I have gutted many mufflers on gas vehicles over the years. It isn't a hard job. All I want is to have my cake and eat it too...



Steve

 

[Mark_Kendrick]

If you want all out performance 5" is the way to go. I use a second turbo as a muffler. the muffler on the 5" s just for show. If you can't open the inlet up, just cram more air through it.



Later,

Mark

 

[Fireman]

Steve,



Hack that muffler off and put in a section of 3" pipe (it needs some bending), you'll like it. The turbo spools up a little quicker and you will hardly notice any difference in the volume, really.



Fireman

 

[skerkvliet]

Steve,



I don't think on a diesel a gutted muffer will sound any different than a 3" stick of pipe stuck in it's place. I have an 01 H. O. that I did that to. With the windows all open it is a little louder, and more so under a good load. With the windows up it is absolutely no different than with the muffler on. I also removed my air box. In its place I have a 4" piece of pvc clamped in the end of the turbo hose and a big open element Amsoil air filter slid on the pvc. It lays on the inner fender where the air box was.



As far as warranty, I've had it in the dealer twice. I flat out asked the service advisor about my mild mods. Doesn't effect warranty at all.



I started out like you - soon you'll want the 4" too!

 

[keimmmo]

Skerkvliet,

Your first post! Congratulations and welcome aboard!



I drive on a lot of rough roads and tow a travel trailer some of the time. I have to hold down the speed to keep from tearing up the trailer!!! I never modified my 160 horse power '92 in 300,000 miles because it had all the power I needed for where I drive!



Now, don't get me wrong. I LOVE high performance! But, I am already thrilled with the power of this truck! For the sake of simplicity and dependability, I plan to keep it pretty well stock.



You have done the two modifications I want to do. Did it lower your EGT? Did it help economy? You have already answered the rest of my questions.



Thanks.



Steve

 

[Turbo Tim 1]

I gutted my muffler a while back, not sure how much difference it made, maybe it spools quicker, not sure, no real noise difference. I used a plasma cutter to gut mine and TIG welded it back together with 309 filler rod. I'm not sure how it would cut with a torch since it is some type of stainless, you could cut it with a thin grinding wheel. Also not sure what else you could weld it with that would work. 309 rod pretty much will stick to anything.

 

[jbone]

Replaced the muffler about a year ago with Geno's "tester", maybe a little louder, but NO drone and one days work with saw-zall... that stainless is a ***** to cut... ... ..... R, J. B.

 

[skerkvliet]

Steve,



As far as lower EGT's, I don't have a gauge - yet! Any time you reduce back pressure, EGT's will always go down. More so under load and more so with a turo.



Economy? I did both of these mods & a Access roll up cover all in one day. The truck had 20k miles on it and I was getting 18 - 18. 5 mpg. It jumped to 20 - 20. 5 mpg. I installed Amsoil bumper to bumper @ 5600 miles. I think this slowed my break in some. Everyone I talked to said they reach max power and mileage around 15K miles. My mileage peaked around 20- 21. 5 at about 25K. The power seemed to peak at about 30K. Hard to tell what was from these two mods alone. I will say this. When we as guys do some kind of mod, it helped in our mind even before the first test drive. I thought it had more snort right away. The next day my bride drove it. She gets back, hops out, and say "WOW! Did that make a difference!" Guess it wasn't just wishful thinking.



I should tell you that the turbo is WAY louder. It dose spool much sooner. You can hear just off idle now. I like it. It did take a acouple of weeks to get used to though.



Good luck!



Also, Steve