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Well, since I have the body off of mine, I am once again playing the "fitment" game of what should go where and in what order should I build... only to determine, as I feared, that it all has to go together at the same time. I figure that the exhaust is a big item that has to be routed. I hate it when exhaust systems have all kinds of obscene bends in them because they were considered last and after the fact. I would prefer this system to be clean, straight as possible, and require minimal bending. That being the case, its a fairly predictable route, straight back along the passenger's side frame rail. Since I am the oddball and went with a driver's side transfer case, I have less things in the way, ie front driveshaft, to have to clearance past. I also want to take the exhaust all the way back and have it exit behind the rear wheel since in Virginia, inspectors and even the State police are very strict on the exit point for the exhaust system.
Because I have the room, and I am planning on tweaking the engine tune later down the road, I decided on going with 3" stainless. The other funny thing is that its cheaper than the 2.5" stainless.. Only thing I can figure is because 2.5" stainless is the big bad nasty stuff in the car turbo, "sport tuner" cough rice burner world and its too small to be common in the Diesel truck world so its an odd ball in between. Anyways, 3" stainless requires some adaptation to my turbo charger. The turbo down pipe on my engine is a weird size (British Cummins) so I had to machine the face of the V band clamp down just a hair to index inside the turbo outlet. Then in order to adapt from the 2.5" V band (because of the clamp size, not outlet size) I made a neat little stainless ring that basically allows a piece of 3" to be welded to the V band adapter.
Used the plasma cutter to knock out a rough circle from some 3/16" thick 304 plate.
Spun it on the lathe to clean up the ID and then used the jaws backwards to Jam it and cleaned up the outside. Perfect fit on the downtube and it indexed perfectly to my machined Vband adapter. Took it one block over to my old College buddy, handed him some SS TIG rods and a Beer and he melted them both together for me.
Because I have the room, and I am planning on tweaking the engine tune later down the road, I decided on going with 3" stainless. The other funny thing is that its cheaper than the 2.5" stainless.. Only thing I can figure is because 2.5" stainless is the big bad nasty stuff in the car turbo, "sport tuner" cough rice burner world and its too small to be common in the Diesel truck world so its an odd ball in between. Anyways, 3" stainless requires some adaptation to my turbo charger. The turbo down pipe on my engine is a weird size (British Cummins) so I had to machine the face of the V band clamp down just a hair to index inside the turbo outlet. Then in order to adapt from the 2.5" V band (because of the clamp size, not outlet size) I made a neat little stainless ring that basically allows a piece of 3" to be welded to the V band adapter.
Used the plasma cutter to knock out a rough circle from some 3/16" thick 304 plate.
Spun it on the lathe to clean up the ID and then used the jaws backwards to Jam it and cleaned up the outside. Perfect fit on the downtube and it indexed perfectly to my machined Vband adapter. Took it one block over to my old College buddy, handed him some SS TIG rods and a Beer and he melted them both together for me.
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