DD Downpipe problems

[TXRam]

OK, here's the deal. I installed an HX40 with DD 4" downpipe a couple of months ago - but. . . I left the 3" system on the truck and had a local muffler shop mate it back up.



Now I've pieced together a 4" system, but that dad-blamed downpipe is crooked - when it turns back horizontal to run under the cab, it is angled towards the passenger side door (about 10-15 degrees I would guess), instead of straight back. The rest of the system is designed to run straight back. And I'm having the worst time trying to figure out how to connect the downpipe up to the rest of the system. And I can't find anyone near me that can bend the 4" stuff. Can I bend it this small amount by heating it with a propane torch? Any other way?



I know other guys have had this same problem.



ANY AND ALL help is very truly appreciated!!!

 

[Vaman]

I had some alignment problems with my downpipe and exhaust too. I used a 4" bandclamp to connect the downpipe to the first exhaust piece. It will make up for any small angle differences (not sure about 10-15 degrees) and, very importantly, it won't stress your turbo and exhaust manifold. Your choices are basically use a bandclamp, get a new downpipe, or stress the heck out of everything and install it as is. Good luck.

 

[John_P]

TxRam:



I don't think you are going to be able "bend" that

aluminized pipe with a propane torch. You "might"

be able to do it with an acetylene/oxygen torch

though. It is going to have to get very hot!!

I had some "minor" problems getting my DD

exhaust on too, but once we got all the ends

pressed in real tight together everything fit

alright. I had too much "slack" in mine, the

whole system was "too long" before the seams

were pressed tight.



I hope this has helped you some.



----------

John_P

 

[Blkdawdg]

ME TOO!

I have the same problem with my downpipe and I've never gotten it to fit right. I've tried everything that I can think of and nothing works. I think I'm just going to call DD and see what they tell me.

 

[work2muchplay2little]

TXRam, I had the very same issue a couple of months ago just like Vaman. I talked to Lawrence, and he said they had just recently had some problems with their source for these. He overnighted me a corrected one free of charge. It was a pain to change the downpipe out again, but DD gets an A+ for customer service. I'd call 'em back.

 

[BIG BOB]

I had the same problem with my downpipe from DD. I could not be without the truck so I went to Napa and got a 4" coupler and 2-4" clamps, I then layed the coupler next to the downpipe and marked where I need to cut the downpipe, I then cut the downpipe, slipped the coupler on, put the downpipe back together loose. I then mounted the downpipe to the turbo, turned the lower part of the downpipe to the angle it needed to be, mounted the rest of the exhaust system and then tightened the clamps on the coupler. Haven't had any problem with it since.



DD also gave me a small refund for my hassles. Great Customer service by DD!





( "small" = moderator edit )

note from moderator: The spirit of this post was 100% helpful and this isn't a criticism -- Just to keep vendors from getting calls "so-and-so got $XX dollars back for whatcahmacallit; how come I didn't get $XX and got $YY?" ... . those things are on a customer by customer basis and it's the objective of the boards price quote policies to let vendors work those things out one on one plus some good info from all of us.

 

[groundpounder]

A small refund?? That is excellent customer service!!!



( "small" == moderator edit )

 

[ACoyle]

When I ordered my Jardine system this week, they told me that they were mounting an HX40 on a Ram on Friday to custom desigh a down pipe. Thye said that the reason for this is that there have been a few problems. Give them a call, maybe they have just what you need.

 

[TXRam]

Thanks for all the help!



Since I bought the downpipe from a guy that bought it from DD (didn't buy it from DD myself), I wouldn't expect them to help me out here. But I do plan on calling Lawrence on Monday to see if he has any other suggestions. If not, I'll probably do the same thing as Big Bob did - just cut in the middle of the part running down by the firewall, and then install a 4" coupler. Then I'm sure a band clamp will make up any slight difference.

 

[Mill Rat]

Alternate bending idea

If You have a decent size INDUSTRIAL electrical contractor in Your area that has a Greenlee Hydraulic conduit bender with 4" shoes they might be able to bend the pipe as You need it.

Just an idea, good luck

 

[bigkavr]

TXR

Another option is to use a piece of 4" stainless flexpipe.

When I built my 4" exhaust, I was concerned with engine vibration/movement twisting the entire exhaust system.

So I put a 10" piece of 4" stainless flexpipe between the

down pipe and the rest of the exhaust system. (just like on the big trucks)

This might also work for you since the flexpipe can be bent somewhat to make up for misalingments. Just put a band clamp on either end and your ready to go..... good luck. .

 

[Archive]

Originally posted by bigkavr

TXR

Another option is to use a piece of 4" stainless flexpipe.

Did/does the flexpipe change the tone of the exhaust at all?

Thanks.

 

[bigkavr]

Rob,



No, the flexpipe doesn't alter the exhaust sound at all.

It just allows a little "give" when things move.