I finally got rid of the factory muffler. After reading all the excellent posts on this mod and taking advantage of great tips from Chuck and Barry (Chuck Berry?) I ended up with an Aero 5050XL. I pretty much knocked off Chuck's parts list with a couple changes. I was able to do the install without using any flex pipe which I might add is not what I would describe as flexible.
Here's the order of my install from the 4" turbo downpipe:
1. 4"-5" adapter;
2. 8" connector
3. 8" 90
4. 10" 90
5. Resonator
6. 12" 45
7. 8" connector
8. Tip
* Used four hangers.
My hat is off to you guys that did this job without removing the fender. I still struggled with it with the fender removed and must have crawled under that a hundred times.
jor
I cheated and had the Cummins shop guy weld up a 5050xl exhaust system. Expensive. Beautiful welds and hanger setup.
I am not as good of an engineer and fabricator as JOR is.
Sure leaves a nice empty hole where the muffler used to be. Nice spot for a welded up Aluminum firewood box. Could be wider than the door opening if one were so inclined.
How is the sound? let's hear a you tube video....Nice job....Working on the gravel, didn't look like it was fun.Your a brave soul
Chris
I personally like the sound of mine, but at Phoenix my brother was guiding me from the rear and said if that noisy thing didn't add a 100 hp, to put the stock muffler back on.
Jor, you might find that the turn down tip makes a dust cloud. I modified mine as I couldn't see out the left rear backing out my driveway.
By the way I still have the flex left over also.
If you make the tip straight out it can add horsepower?
JOR—You always do things the Hard Way. Gravel. Show off! I give you extra credit for toughness and tenacity. How's the growl?
How much did the stock muffler weigh?
Bob....Your so funny..... 8)
Chris. How does it sound? Well, that's a good question. I had drained my radiator in anticipation of flushing the cooling system. My plan was to put some water in and fire it up. Well... (this gets a little complicated) I had intended on changing the thermostat at the same time so I had pulled the hose and fitting off the block. Uh, oh... no thermostat. Guess I better check the book. Turns out I have two thermostats and they are located in a housing below this fitting. No sweat. I'll just put some sealer on the gasket and be good to go. Where is this story going? Well, in order to remove the hose fitting I had to remove the coolant filter. And now the coolant filter has disappeared. It's like some kind of conspiracy. I've got one on the way so soon I'll fire it up.
Crane. I never thought about the turndown-dust issue. I might just do your modification as I live at the end of a 1 1/2 mile unmaintained dirt road. I can just get this 34 footer into our driveway.
Paul: Working on gravel is invigorating!
Old: The factory muffler weighed 42#. I thought it was going to be a lot heavier and was all set up to receive lots of weight. It's no big deal. Anyone taking down a muffler like this one can easily do it by hand.
jor
The U320 weighed a lot more than 42 pounds and was a much larger boat anchor
Thanks jor I was getting the feeling I was inept because my plans seem to mirror yours, just one part short of a full deck. Got 5 projects in a holding pattern, waiting on something or other.
Jor, as long as you're in the neighborhood there might want to take a look at the oft overlooked short coolant ell nicely tucked in behind the alternator more or less.
Mine was noticeable, wife says she can hear me a street over.. No way of sneaking into the rv park at midnight.
Did it help? Not sure but I know it didnt hurt. Bed isnt as hot for sure and sounds good..
Weight on the resonator is probably 10 lb? maybe 15lb? No problem compared to that trash can lead weight I took out..
Presently we are having a mechanic install a resonator and adding the storage compartment in the area where the factory muffler resided. Can't wait to hear and see it! We get her back the week after thanksgiving, ...it's a long list this time ...2 ACs, new refrigerator, lighting, radiator replacement... I'm expecting to get her back in time for the Florida Motorcade rally.
Nice Job John! My only concern would be the omission of the stainless flex after the turbo. I don't know how much the engine can move under changing load conditions, but I would wonder if the hangers have enough give to make up for the use of rigid tubing in place of the flex. By the way, the giant trash can used on the ISC appears to be three times the size of the muffler you removed! I am quite sure it weighs way more than 40lbs. Thanks for the parts list... ^.^d
Don
Checked it out. Looks good. Glad I don't have to change that thing. Gracias, Chuck.
Don, I was thinking that the hanger/isolators should have enough give to allow for a little engine movement but I will watch it closely. I still have the flex which I could use if need be. Thanks for the warning.
jor
Yes, you need to check.
Obviously, the further from center of engine, the more movement that small degree change caused by torque and the slight play in the engine mounts (there to absorb vibration) makes.
Installed a resonator about 2 years ago. NO flex used at the turbo. About 15K miles so far with no issues. That includes a trip to Alaska on less than stellar roads.
Steve
Michael have you had your mechanic apply pressure to the inner cooler? I thought mine was ok until I applied pressure (10lb) and I started finding holes in it. Atlas radiator is 8 weeks out, they have to order the core, which is 4 weeks out, then they build the ends and put it together, another 4 weeks. I have aluminum epoxy coming and plan to try and patch it for one last trip. If it won't hold 40 pounds then we will just be waiting for the new one and won't make Q, I was hoping to meet some of you guys but I guess there is always next year if things don't work out.
BTW if I remember correctly the new one will be 1685 + shipping
Chris
Chris, I have to confess that I barely know what an intercooler is. I got passed over when He was handing out mechanical abilities. I've learned to operate a Porter Cable polisher, though.
It is also known as a CAC charged air cooler
I did go to Wikipedia last night and read an article on intercoolers. I'm on a mission to learn. I've got 18 months to retirement, full-time, and Alaska. I'd better learn what those thingies are back there.
Michael,
Educating yourself on all aspects of coach ownership is a rewarding pursuit, in more ways than one. One of the greatest technical resources we, as Foretravel owners have, is the beamalarm.com Motorhome Technical Help compendium. I know you are probably already aware of Barry's masterpiece, but for newer Forum members it is well worth repeating. I don't think Barry Brideau ever gets sufficient praise for gathering so much useful information into one easily accessed location. Reading through the articles contained therein is the quickest way to get up to speed on owning a Foretravel. We have had our coach for about 5 years, and although I refer to beamalarm.com several times a week, I have a long way to go before I can say I have read it all. I'll add the link below for any newer members who might see this post:
Foretravel Motorhome technical help and information links (http://beamalarm.com/foretravel-links/foretravel-technical-help.html)
As a friend of mine likes to say: "Strong work"! Looks very professional. I didn't need the "flex" pipe either, but did use insulating wrap and a turbo blanket to keep the heat down in the bedroom. As for sound, I usually hit the accelerator in tunnels and underpasses.
I'll take your suggestion and reread the beamkalarm section! Good idea.
Sven,
What was the number and source for your turbo blanket? Mine is on an 8.3 but I wonder if they are much different. It looks just like the one we had on the M11s. Mine is labeled Holset HX40W. Thanks.
jor
Chris, I repaired 4 holes in my CAC about 5 yrs ago with Devcon aluminum filler and tested it next day to 45 lbs with no loss over 12 hrs and the holes were around 1/4" dia . It is as good as new and with the Banks on my 350 I often see 33lbs boost. The engine runs great with tons of power. Clean Clean the area before using filler.
JohnH
All you have to do is search "Cummins 8.3 turbo blanket" and you will get a lot of choices. This one looks like mine:
cummins 8.3 turbo blanket - Bing images (https://www.bing.com/images/search?view=detailV2&ccid=RFu9Hamf&id=05B548572162B87E7B87B89294BFF10A7EF8E48A&thid=OIP.RFu9HamfSuaJFEhwmdtg6gHaHa&mediaurl=http%3a%2f%2fd3d71ba2asa5oz.cloudfront.net%2f12017099%2fimages%2fhx40wt4turboturboc_96c27_speed_daddy_sdd-tbc-hx__1.jpg&exph=700&expw=700&q=cummins+8.3+turbo+blanket&simid=608034386763974686&selectedIndex=0&ajaxhist=0)
Got it. I did find quite a few when I used that turbo model number. Gracias.
jor