Well I jumped in last week and tackled getting rid of the trash can anchored to my coach. It wasn't fun but part of that is because I didn't remove the panel. My 20 year old brain forced my 52 year old body to tough it out...I need to quit listening to that kid.
Once I pulled out the old muffler and parts I called around hoping to find someone with 5" stuff locally but no luck. Ordered 4 band clamps, 1 hanger, 1 45, 1 90, and a short piece of pipe (ID/ID) from a local truck repair shop. I pulled the down pipe off the turbo, wire brushed and sanded it, put a few coats of OSPHO on it, then primed and painted it with high temp paint. I had to cut the 45 and the short piece of pipe some, along with a lot of trial and error but finally got the tip to align correctly. (Original tip was grungy behind the hole but used some turtle wax metal polish and it cleaned up perty) Gonna heat wrap it and throw on a cute turbo blanket tomorrow.
Would have been easier with another set of hands and someone to yell at but just me and my trusty harbor freight jack.
Haven't heard it on the road yet but she sounds pissed at idle...heading to Dumont Dunes next week to play with the toy so hopefully feel some of that quick spool up I've read about on here. I'll also be installing a bully dog tuner wich is suppose to wake it up some so we'll see.
Which resonator did you install?
Just wait until you are 75 and your brain has only matured to 30.
Really good looking installation. I bet it will sound great.
Richard
This project is on my list.
Nicely done Dylan, you'll love the sound and improved power response. However, correct me if I'm wrong, but I don't see any flex pipe in the pictures, so do you have 6+ feet of pipe and the resonator hanging from the turbo? The engine does torque and vibrate a lot, so please keep a close eye on the down pipe from the turbo and all the clamps, and seriously consider replacing the first 45 deg elbow with some s/s flex pipe...sooner than later. Here's how I did mine 3 1/2 years ago: Woody.
I did buy a couple feet of flex pipe but didn't use it, now you got me worried about the movement. After looking at yours I feel I could have used a long piece of flex pipe in place of the 45 and 90 straight to the resonator..not sure though. I'll definitely keep a close eye on everything and re-torque at my first stop.
I guess with it so rigid my chrome tip may rub on the fiberglass when engine twists from torque correct?
Just to let you know configuration...down pipe to 45 to 90, the 90 directly to the resonator, then needed about 4 inches of straight pipe to reach the tip.
I did a similar installation. I ordered flex pipe, but did not use it either. It does vibrate a bit. I took mine to a muffler shop, they cut and fitted the pieces I had and welded it, no clamps and no flex. We will see how it holds together. I have about 300 miles on my job.
Do keep a check on the torque, as I clamped the resonator in place to travel to muffler shop.....blew it off first acceleration on the highway. Luckily I had it strapped good with hanger strapping.
I really didn't think this through, now that you mention it my connection from my 90 to my resonator is probably where it would pop off. The 90 is ID on that end and the resonator is OD so it just slipped in and I used a band clamp as the connection. There are no "slits" on the OD of the resonator so I can't imagine the band clamp squeezing hard enough to keep it secure if there a ton of back pressure. Think I just assumed there wasn't going to be much back pressure with essentially straight pipe from the turbo. (guess i thought the resonator wouldn't be a restriction) Wonder if I throw a hanger clamp on there as well and tighten the hell out of it to "squeeze" the resonator onto the 90 if that would hold.
I used the same clamp you described. I thought I cranked down on it but it blew off on my first acceleration. I assumed that I did not tighten enough, because FOT used a similar clamp on the original system along with a very short 6 inches or so flex tubing. But the garbage can was bolted in place to the frame as you already know. The resonator I used is 18 inches, surprised at the back pressure also. At least with a hanger, you will not lose the resonator.
I have the Aero 5050XL also. It is a loud beast, but does the job.
Nice job!
Keith
If you had it to do over would you choose something different?
I would prefer a real muffler, but it didn't appear to be an option at the time. The Aero 5050XL was recommended by Foretravel because the regular muffler was no longer made. The resonator does the job, but I may see what truck mufflers would fit in its current place.
There is an industrial muffler shop near me and when I needed a muffler for my Monaco they made
one for me as they didn't have one in stock. Maybe you could fine such a shop near you.