Update: 4 inch cast elbow - 4 inch downpipe

[Tomeygun]

Little update here:



I got the cast factory elbow from Dave @ dieselpowerproducts for $20, and the dowpipe from my parts dept for $60 or so...



in to the install:

1) Removed the old exhaust from the cast elbow back, removeed cast 03 elbow and, not too bad, reuseable clamp was a bit stuck, but came off

2) Went to install 05 cast elbow, but had to grind off the lower "locating pin" on the elbow, the one that i guess makes sure the elbow is degree'ed correct

3) install re-useable clamp between cast elbow and turbo



4) cast elbow is all on and secured, on to the downpipe, slid the downpipe up into place and "tried" to fit the hanger in the stock position, NO GO, hanger is off by 1/2 inch, I had to remove red rubber plug to get a flush fit of flange to cast elbow...



At this time all seems ok, (except the ill-fitting hanger), BUT as I am installing the clamp to secure the downpipe I find that it is too small - they ordered me a clamp for a 3. 5inch flanged pipe... I need of course the 4inch flange clamp !

After I get that clamp, all should be good



BY THE WAY, to limp to work I used the old clamp and a coat hanger to hold the new downpipe on, and I drove to work with just the downpipe -- , Like a darn school bus (fooled a few kids, :-laf )



BUT, egts would not even touch 1000 on a 90mph run on TSTlvl 6/5 with that (of course this was only a 3 foot long exhaust system, )



Parts list -

4. 5-05 cast elbow - $20 from ??

Correct clamp - 52121285aa

Dowpipe - 52121600aa



So now I have a full 4inch start of an exhaust system, and the egts are looking to be worth it



I will post an update of egts with full pipe on, cya!

 

[SRadke]

BY THE WAY, to limp to work I used the old clamp and a coat hanger to hold the new downpipe on.

Crazy tom, only you lol. :-laf



-Scott

 

[Tomeygun]

crazy huh !?!?!?



you call me crazy ONE more time, and I think i will leave it that way !!! I will put a turn out on and it will serve as a foot warmer for passengers as they wait to enter,

 

[DaveMorris]

Tomey,

Talk to me buddy, this sounds like (almost) a bolt up swap... Why are you doing it?? ETG's??? or something else??? are you still using the stock turbo??? I am close enough to just stop out and take a look at that monster... are you spooling up any faster???



Thanks

Dave

 

[Tomeygun]

why ? (it seemed like a good idea at the time)



Really though, Because I thought that it would be an easy and in-expensive swap out, And i thought it was wierd to spend money on a 4 inch system when the first 2-3 feet was 3. 5 inch -

And I also thought the restriction (3. 5 outlet on the cast elbow) was messing with the wastgate operation with the TST box on...



AND It would only make sense that the full 4inch system would move more air, right?

That 3. 5inch outlet on the elbow certainly was not HELPING the exhaust flow!!



Because only the downpipe is on, i have no info on spooling, EGT, at this point, all looks good though



I will post an update when the full system is on (5inch pipe ending in front of rear wheel)

 

[kblranch]

Tomey :

I am doing the same install on my 2004. I have all the same parts and I also ordered a 4 inch 409 ss cat elimination pipe and a 4 inch cat back 409 ss exhaust system from DPPI. Is it possible that the little hanger bracket that bolts to the block to hold the down pipe is different for the 2004. 5 and up ? If it is would you possibly have the part number ?

 

[Tomeygun]

Tomey :

I am doing the same install on my 2004. I have all the same parts and I also ordered a 4 inch 409 ss cat elimination pipe and a 4 inch cat back 409 ss exhaust system from DPPI. Is it possible that the little hanger bracket that bolts to the block to hold the down pipe is different for the 2004. 5 and up ? If it is would you possibly have the part number ?

Nope, same part# and same area it attaches to, BUT i did grind off the other tit on the inlet on the elbow, and the fit is a bit better - I can rotate it enough that the hanger slid in... NOW on the the 5inch extention...