Not happy with Stans exhaust fitment

[JAlderman]

I ordered stans exhaust for my 93 seeing how thats the only option there is for a true 4" turbo back. After reading about all the happy and satisified customers how could one go wrong.



I started my day early looking to get in some quality time wrenching. I opened the box all parts where there, so out came the sawzall and out came the stock system easy enough. I losely mounted the down pipe, figured out the jigsaw puzzle to get around the transfer case then I moved on to the muffler. Thats when it all started, the inlet side was never flared to fit over the pipe. After wasting a quarter tank running around town trying to find a 4" expander, I got creative and made the opening big enough to slip over the pipe. The weld on brackets aren't right and they are both on the same side so the muffler wants to twist on the rubber hangers. I stopped there and walked away before something bad happend :{#@$%!



I could fix the brackets tommorrow with my welder no big deal, you get what you pay for and I payed to much for these quality control issues.



I tried to call but it is saturday and now I have to wait until monday. I'm glad this isn't my only mode of transportation.

 

[Trask]

I just installed the 4" system on my 92 W250 4WD ex-cab. It was a jig-saw puzzle, but I got it all on with no big problems. My muffler didn't have any flare, and the inlet pipe isn't stepped down - but the pipe OD fit the muffler ID fine.

I had a problem with the tailpipe hitting my aux. fuel tank - but that's not Stan's fault since the tank was not there originally.

I also made a few extra brackets and hangers since I didn't feel what came on the muffler was adequate.

I also got Stans system for my 94 Ford with the 7. 3 IDI and it all went on OK.

None of this was what I'd call exact bolt-on, but I guess I didn't expect it to be. All went fine with some slight mods.

I can email you photos if you want (of the added hanger on the muffler).

 

[Tippin Spotted Cow]

Every time I get under my truck to work on the exhaust it always ends the same way... profanity use and alcohol consumption. I live in Wisconsin, and every year when it snows they throw down enough salt to sink a battleship, and my flex pipe rots and falls apart. So every January I'm blessed with the opportunity to lay in the snow under my truck in sub-zero temperature so that I can sit at a stoplight without aquiring cancer from the smoke in the cab. I have a 4" system that'll take it from turbo to stacks (sans the flex tube) sitting in my basement right now, and as much as I like frostbite and all, I think I'll wait until spring to partake in the wonderful festivities that are exhaust system repairs.

 

[Trask]

We have as much road salt here in New York, and perhaps more. Many of our dirt roads get salted in the summer too.

I have several vehicles that never get driven in winter or on salted roads in the summer. For the ones I DO have to drive in it - they all get stainless steel - anything else is waste of time and money.

In regard to flex-pipe, I use marine-grade antimagnetic Stainless Steel and I've got it on my trucks for over 10 years old with no rust at all.

 

[PToombs]

Cow Tipper, -laf) wouldn't it be easier to prevent working in the cold by replacing the flex pipe in ,like, October?

Just thought I'd throw that out there to help you out!

 

[Tippin Spotted Cow]

In October it's fine... all my parts wait until January to break on me. I recall replacing my steering gear last year in -20 (actual temperature, not wind chill). The steering gear was find in October though. I've thought about stainless flex tube, but I change my exhaust more than women change their hair color, so I find it hard to spend the money when I'll be ripping it out of there the next time I want to change things up a little. This summer though, they're going from 4" stacks to 5", and all 4" plumbing under the bed. and thats how itll stay for a while I think.

 

[JAlderman]

Well to get MY thread back on track, I came up with a straight pipe option thanks to some left over pipe from a previous truck and a coupler from NAPA. The straight pipe sounds awesome and doesn't have the drone my 05 did. I did the 16cm turbine housing upgrade while I was there. All I can say is holy EGT drops batman, must be 300 degree difference. With a stock setup on my VE pump I hit 20 psi WOT and 900 degrees. Very nice.



Thanks to trask for the pics, it confirmed the placement of brackets on the muffler aren't right. The weight of the muffler and flexible rubber mounts will not hold it right. And it simply looks like crap.



I will be giving stans a call to fix the problem with the muffler.

 

[MMeier]

I just installed the 4" system on my 92 W250 4WD ex-cab. It was a jig-saw puzzle, but I got it all on with no big problems. My muffler didn't have any flare, and the inlet pipe isn't stepped down - but the pipe OD fit the muffler ID fine.

I had a problem with the tailpipe hitting my aux. fuel tank - but that's not Stan's fault since the tank was not there originally.

I also made a few extra brackets and hangers since I didn't feel what came on the muffler was adequate.

I also got Stans system for my 94 Ford with the 7. 3 IDI and it all went on OK.

None of this was what I'd call exact bolt-on, but I guess I didn't expect it to be. All went fine with some slight mods.

I can email you photos if you want (of the added hanger on the muffler).

Post the pics here!

 

[Philip]

I have the same system. All my orginal hangers were gone so I just used heavy unversal hangers. I haven't had any problems with the brackets on the muffler. Even being installed the way they are. The issue I had was the tail pipe was 5" to short before the axle and 5" to long on the drop after the axle. Plus the tailpipe would have went right threw the center of a mud flap.



I didn't even bother calling them. I didn't want the second gen style tail pipe anyway. I just found a place that could work 4" pipe and had a 1st gen style tail pipe made to fit.

 

[Forrest Nearing]

Tippin, wouldn't it be easier to just use stainless flex and band clamps?

 

[Philip]

Now that you have found how much a little air flow improvement will do its time for the intake side of things.



Here is a pic of the stock 1st gen air intake horn from the business side. The other air horn in the same pic is a 99 24 valve air horn.



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Member TWorline can make the IC tube to fit it. Or he also sells what he calls coolztubes.



BTW the air horn was good for a 50 degree drop in EGT's at WOT on my truck.



Here is a pic of it installed on my truck.



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[MMeier]

Phillip

By chance, any idea how much different that intake horn is from a regular 12 valve airhorn from a 2nd gen, 12v? Sourcing a chrome kit here soon and want to use the chrome piece in it on my '93!

 

[JAlderman]

I have every intention of making it breath better. I did the same to my 05.



Well I called stans headers today and they were shocked that this happened. They are willing to pay for everything provided that I am right when it returns to them. And they will pay for shipping both ways. Theres a good 2 week wait for something I'll never use seeing how I like the straight pipe for now.



More to follow.

 

[Philip]

MMeir the 12 valve air horn has a large mounting bracket on it. The later 24 valve doesn't it just has the one extra bolt hole you can see in the pic.



Watch on ebay there are both types listed there pretty regular. Then you can get an idea of how big that wing type mount is.



The aftermarket air horns will work also. The bolt patterns are the same for all years. Just get the correct bolts for the one your decide on. On the one I used two of the stocks bolts worked. I had to pickup the two longer bolts.



I figured that Stan's would try to make it right.

 

[Trask]

Many photos 2st set

Post the pics here!

Here are the rest. By the way, I'm not "Trask" although that's how I'm registered. That's the guy I bought this truck from in Vermont last year. He was all paid up with the forum and I'm using it until it expires. Not that it matters I guess, but I'm John in New York State, not Trask in Vermont.



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