Input wanted: New exhaust manifold?

[JDancoe]

The turbo on my 1st Gen is wearing out. Showing some oil. I have purchased a factory-new turbo, with a a smaller 18CM housing. (My original is a 21CM) I also have a 16CM housing that I could install at the same time.

I'm also considering replacing the exhaust manifold with one of the BD manifolds from Geno's.

Question is: Does anyone have any experience with the BD manifold? Is it worth the price-$500. 00?

The truck is basically stock 92 W-250. Getrag 5-speed, 3. 54 gears, pump turned up slightly, 3" exhaust with muffler removed.

It will be used for towing a 28-foot travel trailer that weighs 6000 - 6500 lbs. (Depending on trip plans and extras carried). I feel I'm a gentle driver, and am interested in good fuel milage and some power improvement when towing, and low EGT.

My last tankfull of fuel, towing a small cargo trailer and with the truck & trailer loaded with furniture & household goods (more bulk than weight) was 22-MPG. Overall average since I've owned the truck 292,00 miles @ 18. 67-MPG. Last trip with the travel trailer (to the 1st Gen. meet in Iowa) 2330 Miles @ 11. 1 MPG. I generally drive the posted speed limit, +/- 5 mph.

Also have been considering a new exhaust system. The original is getting a little rusty even being a Arizona/Southern Colorado truck for all it's life. It has an exhaust brake -3". Would going to a 4" exhaust offer any benefit if the exhaust first has to pass through a 3" brake? (I DO NOT want to give up the exhaust brake!)

Any input appreciated. Thanks, Jack Dancoe

Jack

 

[JWiegel]

The BD manifold is worth it specially if your running a exhaust brake it will expand and contract with heat, 4" exhaust will help keep EGT stay slightly lower but the real benefit will only help if you do a complete 4" turbo back

 

[Bob Beauchaine]

I have an ATS 3 piece ported exhaust manifold, a 14cm2 hotside and a 4" exhaust and my mileage average is about 19. 5 mpg in mixed city and highway driving. It seems as if my truck likes driving at the same speeds as yours.

That being said I would go with the 3 piece ported version exhaust manifold and the 16 cm2 hotside. The only other thing I would recommend is going with a 4" exhaust. With the 4" you should see a drop of about 100+ degrees of EGTs over the 3" exhaust.

I missed the part where you have and want to keep you exhaust brake I am running a BD exhaust brake bolted to my 14 cm2 hot side. My answer was to have Rip at Source Automotive build and install a 3" by 4" 2nd gen down pipe and a 4" exhaust engine to tail pipe.

Bob

 

[James1]

I have an ATS 3 piece ported exhaust manifold...

Sorry for the thread hijack. The ATS website shows no exhaust manifold available for a First Gen -- will their exhaust manifold for a Second Gen (1994 to 1998) work on my First Gen?

 

[Bob Beauchaine]

As far as I know it should fit, but I would call and talk it over with ATS. If they could send the manifold already put together I would go that road. I would also go for the ported version - you will be impressed.



Bob

 

[ENafziger]

I'm not sure you'll see any benefit with a 4" exhaust if you're still on the H1C turbo. It simply can't move enough air to cause the 3" exhaust to introduce backpressure. For the price/hp or price/economy gain, there would be better places to put your money. That being said, if your exhaust needs replacing and there's not a big cost difference between 3" and 4", it's your call... but I don't think you're going realize an improvement anywhere.

I went with this one for $270 that offers the slip-joint benefit for expansion. http://www.dieselautopower.com/product_p/dps-12v-rough.htm

--Eric

 

[Shadrach]

Yes all 12 valve use the same exhaust manifold. If you want a real nice one and can afford it check out this one http://steedspeed.com/cummins_straight_turbo_flange We put one on my buddies 93 ( which has a 96 engine ) that coupled with a cam changed lowered his EGT's almost 200*F. We used 3rd gen bolts and spacers and had to bend the oil feed line a bit. It is real close to his Jake but no problems so far. David



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[RWherley]

As far the exhaust pipe it self, I made my own from a system taken off 3rd gen with a little work done to the fit is good, it sounds good and it was cheap.

 

[James1]

As far as I know it should fit, but I would call and talk it over with ATS. If they could send the manifold already put together I would go that road. I would also go for the ported version - you will be impressed.

I'm not sure you'll see any benefit with a 4" exhaust if you're still on the H1C turbo. It simply can't move enough air to cause the 3" exhaust to introduce backpressure. For the price/hp or price/economy gain, there would be better places to put your money. That being said, if your exhaust needs replacing and there's not a big cost difference between 3" and 4", it's your call... but I don't think you're going realize an improvement anywhere.



I went with this one for $270 that offers the slip-joint benefit for expansion. http://www.dieselautopower.com/product_p/dps-12v-rough.htm

Yes all 12 valve use the same exhaust manifold. If you want a real nice one and can afford it check out this one http://steedspeed.com/cummins_straight_turbo_flange We put one on my buddies 93 ( which has a 96 engine ) that coupled with a cam changed lowered his EGT's almost 200*F. We used 3rd gen bolts and spacers and had to bend the oil feed line a bit. It is real close to his Jake but no problems so far.

Thanks for the replies. I realize we've got two themes going here (exhaust manifolds and 3" vs. 4" exhaust tubing size); I apologize.



I'm not attempting to improve performance; my truck is bone stock. (I am always interested in improving fuel economy however. ) My OEM manifold is very badly rusted and I'm simply looking down the road toward replacement. And when I went to the Geno's website, the 3-piece BD manifold and the Cummins replacement manifold were essentially the same price -- it seems a shame to pay more than $500 and not wind up with an upgrade?



I suppose I'm looking for opinions -- BD manifold vs. ATS manifold vs. BD stainless manifold?



Thanks again.

 

[Joseph Donnelly]

Definitely use the 16 cm2 housing. I like the BD manifold because its passages keep the gases tight before the turbo. Some manifolds allow the exhaust gases to expand and then more work is done to squeeze them down for the entry to the turbine housing.

 

[RWherley]

I was at a truck show and talked to a BD rep, he said unless your truck is turned up a lot there is no point to the stainless and that the iron one will be just fine.

 

[HHhuntitall]

If you tow with your truck, the upgraded exhaust manifolds are, IMO, mandatory. The expansion of the factory exhaust manifold can cause constant problems over times... . I think either the BD or ATS would be a good replacement. I've installed several, and haven't seen any problems with the gaskets, as is so common with the factory manifold.

As for the turbo, I'd go for the 16 or 14cm housing, especially with stock or slight fueling. It allows quicker spool up and should help on bottom end a little. Upper end is very seldom a concern with the VE pump. For the money, I'm not sure the BD or ATS is worth it, but if you have no other options, that's the way to go. Here in my shop, I also offer a 3 piece, Chinese casting, a good bit cheaper that looks identical to the ATS... ... If you have a local shop, you might ask around.....

As for exhaust, if you don't have a 4x4, you can upgrade to 4" fairly easy. I think I can get a whole exhaust kit for that year that I sell around $300 with muffler... . (NO, I'm NOT trying to sell you something, I'm just giving an example of what I'm passing on in my shop!!) Check out Summit Racing for some pricing, too. I think they carry Diamond Eye kits for a little less... ...

 

[RSchwarzli]

Sorry for the late reply here... . been away for a few weeks!

I have a ATS manifold on the crew cab, and a BD on the 1990 as that was all that was available in a hurry when mine started to crack a few years ago as I was leaving for a cross country trip.

I do like the ATS better but have no complaints so far with the BD one. Granted, not really that much that can go wrong with a manifold like that but... .