Exhaust question

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I've been considering an exhaust system upgrade to one of the aftermarket 3. 5" systems when I began to wonder if it is possible(ok, anythings possible, maybe easily adaptable) to use the stock 3. 5" system from one of the 2nd gen trucks that have moved up to an aftermarket setup. Anyone familiar enough w/ both trucks to know if this is a possibillity or just a bad idea. Thanks.

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93 D-250 club cab. Auto 3. 54 gears. 75k miles. Bone stock.

 

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If you get an exhaust system from a 24 valver, you can also install a catylitic converter! Don't know why you would want to do this.

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89 D-250 LE 5 speed 3. 55 Limited slip, K&N, straight piped, Boost/Pyro. & 16cm2 215K and still going. 91 W-250 5 speed, 4. 10 Limited slip, 16cm2, 6" Skyjacker lift, RS9000, Dump bed, 18K original mi.

 

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24 valves don't have cats. Only trucks manufactured from 1-1-94 thru 12-31-97 have cats, these were all 12 valves. The 24 valve trucks do use a resonator in the same place the older trucks have the cat.

Pete

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'97 2500 CC 4X4 5spd Sport
'83 K5 Blazer 350 TBI (ex 6. 2), 39. 5 TSLs, 3" lift, Dana 60/GM 14 blt, Detroits

 

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I stand corrected, I knew they had cats on the second generation trucks, but I did not know they had them as early as 94, and deleted them on the 24 valve.
Terry,
The cheapest and easiest way to upgrade your exhaust is to find a muffler shop that does 3" pipe, and have them make you a straight pipe (flared at both ends). I cut my factory exhaust off at the lowest, most forward piont. I also removed the muffler from the tailpipe (cut the muffler, salvage the tail pipe). I then installed an 80" long section of straight pipe between the two cut sections (may need to add 18" more for the ext cab). I purchased aftermarket hangers and was able to mount these directly to the former muffler hanger locations. The truck sounds -well- like a truck. Not very loud in the cab, but loud if you are behind it and the driver has his right foot mashed to the floor.

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89 D-250 LE 5 speed 3. 55 Limited slip, K&N, straight piped, Boost/Pyro. & 16cm2 215K and still going. 91 W-250 5 speed, 4. 10 Limited slip, 16cm2, 6" Skyjacker lift, RS9000, Dump bed, 18K original mi.

 

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Getting that exhaust out quickly and smoothly is more important than you may think. You may see more lbs. of boost than you might expect. Even straight piped 3" is holding some back with all those bends around the transfer case and the rear axel.

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• '93 250 LE 4x4 5spd 4:10 Loaded,dual 5" chrome stacks,12cm² turbo,PW injectors,K&N,pyro/boost,US Gear E-Brake,tool box,CB,10" AR rims, 285/75/16 Bf goodrich. "wirenut_21529" on Yahoo Messenger
• '96 Ford B-Series school bus (5. 9 Cummins!)I'm gonna Bomb it!
• '94 GMC 2500 6. 5L Turbo

PICTURES.

 

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OK, what I'm seeing so far is that the effort isn't worth the hassle. I'm leaning towards just replacing the stock muffler w/ a free-flow one(I've seen a walker part # recommended but can't remember the model or name) and try to find a shop to bend a new tailpipe. Does this sound like the most cost effective way to free up the exhaust w/out it getting obnoxiously loud? I do like the idea of the complete aftermarket 3. 5" exhaust systems (BD), but wonder if their really worth the $350. Thanks again for the opinions.

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93 D-250 club cab. Auto 3. 54 gears. 75k miles. Bone stock.

 

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I think upgrading the exhaust would be a very good idea. As wirenut mentioned, there are alot of bends around the transfer case on the stock exhaust. You might have some luck trying to find a local muffler shop that could build an exhaust for you cheaper... . who knows. I know when I get some more $$$, the exhaust will defintely be replaced.
cody

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91 4x4, 5 speed, 3. 54 gears, pw injectors, 12cm turbo housing, K&N air filter, "tweaked" pump, isspro boost and pyro gagues w/A pillar mount, straight piped 3' exhaust

 

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I am very happy with my upgrade. I went to local shop and had them create new 3" right from the front down pipe down & around transfer, straight back to a DynoMax freeflow muffler. Then up and over rear end and out behind right rear tire with a 5" chrome tip. (I call it my paint can). Asked to be as freeflowing and straight as possible and they did a great job. Cost less then ordering and haven't had any problems since it is all completely welded together. SOunds GREAT with the DynoMax muffler. This also increased my Boost by a few numbers, not much by numbers but more by butt.

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Scott
92 Ram, Bright White, Club Cab, LE package, 4x4, 130K, 3. 54 gears, Auto, Extra transmission Cooler under bed, 285x75x16 Cooper Discovery A/T, 16X10 American Racing rims, Rancho RS9000 all around, Tekonsha Brake Controller, Running boards, Lund Sunvisor, Marker lights, Lund bug deflector, Tonneau cover, Full cap, DynoMax muffler, 5" Chrome tip, 16 cm Turbo, Isspro Boost gauge, 23 lbs Boost, Pump Adjustments, Sprayed in Bed-liner, Rubber mat

'SHAKES, RATTLES & GOES'

[This message has been edited by NuttyMopar (edited 11-29-2000). ]

 

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I believe Terry has a D-250, so he does not have to worry about making the ugly bend around the transfer case. On the two wheel drive trucks, it's a straight shot from the bell housing to the tailpipe. Although the stock exhaust makes a few bends between these two points, you can make it one straight shot. I was originally going to have a muffler shop install a flowmaster muffler and a 3 1/2" tail pipe for $400. 00. Instead, I paid $20. 00 for the pipe, and $12. 00 for the clamps and hangers, and had it installed in less than 3 hours. It's all a matter of what you want to spend on exhaust. At first I thought it was a little too loud (especially with the R/H window down) but after a while, you begin to like it.

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89 D-250 LE 5 speed 3. 55 Limited slip, K&N, straight piped, Boost/Pyro. & 16cm2 215K and still going. 91 W-250 5 speed, 4. 10 Limited slip, 16cm2, 6" Skyjacker lift, RS9000, Dump bed, 18K original mi.

 

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I have a 92 W250 with open exaust I got a tailpipe from the dodge dealer for under $100 it is for a 97 and it fits pretty good it is 3 inch with a 4 inch tip I got a peice of straight pipe at the parts store fore $4. 00 a foot cut the pipe behind the transfer case and start there

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The D models are easier to BOMB. I cut out the muffler with a straight 3" then a 3-3. 5" adaptor to the 3. 5" Ford pipe up-over and out the side from a stinger kit. The beauty of the Dorf pipe is that the hanger is further up and I can easily slip the chrome tip on. Only about $180 after all the parts.

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Jason Hoffman
Lil' Mack - 89 D250LE 5 Spd 3. 54 Reg Cab. K&N,"tweaked pump", BD Injectors, Banks Pyro/Boost, 3. 5" Exst tail section straight. E&M Custom seats. Bosch H4, PIAA 80W/80W HdLites. 100W Drv,55W Fogs. 237,500 miles (380,000 Kms) 7850 Hrs.
Cummins Power Booster member.
The Original Turbo Diesel

Lil' Mack Pics

 

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I am running a straight 3" pipe without muffler and no tail pipe(coming out in front of the rear tire). I am told it can be a little loud, but with a 179" wheel base,it dosen't bother me any #ad


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1985 DODGE 1 ton Crew Cab(imported from California with no rust) W/8' box converted to 4X4(wasn't that hard to do!) in 1999,converted to a 1991 Cummins Turbo diesel & 5 speed Getrag in 2000(wife can't drive a stick . 4:10 gears, limited slip rear end, 205 transfer case, 16" Goodyear GSA Wranglers and LE Package and a Sony CD Stereo. A one of a kind truck(Wish Dodge would build a new Crew Cab in 1 ton. Last year for the Crew Cab was 1985)If you want to know why I did all of this, 2 kids, one on the way and I can't stand Ford and Chevy. Kyle Hoover ,Fruitport, MI

 

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Hey bud!
I had the BD 31/2" mandrell bent system installed on my 93 clubcab a few years ago. I did see a noticable diff. in the way the turbo spooled up and and bit more boost. I think it will definitely help the monster breath better to be sure. If I were going to do it again I would go 4" now. All in all though I was pleased with the effect as it allowed a bit of pump tweaking and did not result in high smoke/temps. FWIW.

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93. 5 D250 4X4,HD Spring Pkg, Rancho 7000's, Rear Swaybar, Dual Shock Front Stabilizer, BD Injectors, 31/2" Mandrel bent exhaust, 16cm 'Hot End', Modest Pump Tweaks/Timed, K&N Air, Isspro Pyro,Tach,transmission Temp, Auto Meter Oil Filled Boost Ga. , 3:54's, 4 Speed Auto, Clubcab, Aftermarket Reclining Buckets w/ctr Drop Down seat/console, Black over Silver, 21psi,285-65R-16's,American Racing Clear Coat Mags, Amsoil 15W-40HD Marine,12,000 lb. Warn Winch,KC Spots. 97,000 Kms.