What exhaust size and muffler

[fastmark]

Well my crew cab conversion is down to the exhaust now. I think I have decide to go with the BD brake. Does it mount right at the turbo? Do you keep the original down pipe? What size pipe should I use? My local shop can bend up to 3". I doubt if anyone makes a bolt on kit for a 91 4 dr CTD. Can I just buy one for a ext cab and get a shop to add a few inches? I hate to sound old, but I don't think I can take a straight pipe with no muffler. Who makes the best muffler that is quite and has low back pressure? How about sources on these parts? Any oppinions will help. Thanks Mark Faught

 

[BigRig]

I can't help you on the exhaust brake but I can tell you that the exhaust system from BD is very nice. It is mandrel bent, which most exhaust shops can't do. It costs a little more money, but fits perfectly under the truck with no monkeying around. I took the kit to a local shop and they were wondering where the heck I got that stuff. I would think that in the straight section of the system, you could add some length relatively easy. If it wern't for this club , I'd still have an old sluggish truck. Thanks everyone for your help. Scott

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'92,CC,4x4,ctd,3. 54's,16cm,lucas injectors,isspro boost and pyro gauges,firestone air bags,BD 3. 5 exhaust,factory tach

 

[R.E. Miller]

I have both the Jardine Performance 3. 5", and the BD 3. 5" on my trucks. But systems are high quality, but the Jardine is easyier to intstall and it comes with a walker? muffler that is straight thru, real neat and fast for a straight pipe install.

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1992 W-350 Club Cab Dually 3. 5" straight pipe(thanks jardine!)
W-350 8' contractors dump with 3. 5"BD exhaust, 16cm^2 housing, DI pyro&boost
Russell

 

[Matt S]

I can't imagine any difference in exhausts from a regular cab to a club cab to a crew cab other than a bigger piece of straight section. I'd find an exhaust you liked and just get an extra straight piece for the middle as the ends should be the same. I have an exhaust from Jannetty Racing with a walker muffler that isn't noticeable from the cab with the window up.

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90 W250, 5-speed, isspro gauges, 16 cm2, K&N, Borgeson shaft, JRE 3" exhaust, Banks Intercooler, Lucas injectors

 

[BillyKidd]

Just my two cents worth but here goes... I put a cummins in a 74 Crewcab shortbed. The exhaust from Banks (3")that normally fits a club cab long bed bolted right in and fit perfect. The distance from turbo to tip is the same for CrewCab Short bed as ClubCab longbed so any exhaust system you choose should be the right length (if your CC Shortbed)Long bed CC would take extra length and handled as everyone else has stated.

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93,CC,4X4,LE,Auto/3. 54. Banks intercooler/exhaust,K&N,PW injectors, 14cm2 wastegated turbo, "timed" pump, Walker "flow-thru" muffler,Emerald Grn. w/ SS running board,Grizzly Grill Guard.

 

[Jones]

Greetings All,
I'm stuck with 3" because of clearance problems until I get past my x-member but I've found a pretty neat set-up I'd like to share. I picked up that little resonator that Dodge puts ahead of the muffler on '98s, it's 3" in and 4" out. Walker now has a 4" mandrel bent tailpipe, P/N 54 150.
The result is a exhaust system that breathes good and is quiet yet lets you know when you're getting in to it. Not sure what the tail pipe retails for but my shop cost was $39. 99. Hope this helps or at least gives somebody an additional way to go.
Jones

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Jones
'84 Ramcharger w/CTD, non-gated 12, torqflite, NP205, Dana 60 and 70 w/ 3. 07s. Straight piped 3" to x-member 4" the rest of the way.

 

[Old Nordby]

Go with what these guys are saying if in your budget! Your local shop will not be able to bend a 3" without crushing the pipe right where the factory did it as it bends over the axle. They may crush it less, but It would be quite a bend for them to get it done without messing up the flow.

jon

 

[CrewCabDiesel]

I ordered my exhaust from Stan's and it worked out GREAT ! I had them make an exhaust for a extended cab and had them make a 4' pipe to make up for the extra length. Also I had them make a replacement pipe for the muffler #ad
. Total cost just under $290 With 3 day express shipping to Michigan.
Kyle

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1985 DODGE 1 ton Crew Cab(imported from California with no rust) W/8' box converted to 4X4 in 1999. Converted to a non-intercooled 1991 Cummins Turbo diesel & rebuilt 5 speed Getrag in 2001(wife can't drive a stick . Freshly rebuilt and Balanced Cummins, Rebuilt NP205, Rebuilt Injector pump and tweaked, Matched Injectors, 3" New Mandrel Bent Exhaust,no muffler, Borgeson Steering Shaft, K&N Air Filter, 4:10 gears, limited slip rear end, 16" Goodyear GSA Wranglers, 16K Reese 5th Wheel Hitch,and LE Package and a Sony CD Stereo. Next add-on some “Banks” toys ! If you want to know why I did all of this, 2 kids, one on the way and I can't stand F**d and Ch**y. Kyle Hoover ,Fruitport, MI.