What did you do to your coach (Dave K's resonator upgrade) today.

Topic: What did you do to your coach (Dave K's resonator upgrade) today. (Read 1349 times) previous topic - next topic

What did you do to your coach (Dave K's resonator upgrade) today.

January 05, 2012, 02:20:26 am

Removed the old muffler and plumbing and took it to the transfer station. New resonator and plumbing going in...

Sure is a lot easier with the side panel off!

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #1 – January 05, 2012, 11:16:02 am

Dave-nice to see you agree with my idea of taking off the side panel. I have done that on both sides for the resonator on one side and when I did the CAC repair on the other.
Don, it is very easy to do . First take off the peice of trim above panel (could be 8ft long) then the screws below that and any along the bottom of panel and the trim in vertical position. Remove all caulking. You will also have to remove screws by the door opening for last compartment (just use your common sense as to what may be needed as each panel is different). The panel should just lift off, and store carefully.
John

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #2 – January 06, 2012, 03:02:43 am

Quote from: acousticart – January 05, 2012, 10:11:54 am

Dave K, I am interested in hearing more about your resonator project. What resonator and plumbing are you using? Also, how hard is it to remove the panel?

As John says, it's pretty easy to remove the side panel, and what a difference in workspace!

I got resonator, flex pipe, elbows, pipe, reducer, clamps, etc., from Truck and Trailer Parts in Tucson (we are down in Benson now). Don't remember what brand the resonator is - probably Walker equivalent, and short. Tomorrow I will fab the hanger structure. I'll post pictures when done. And we will see how loud it is... I do know that the rig is much lighter on that side with the old muffler out! I'm guessing 80-100 lbs or so for the old muffler, but then the new resonator and plumbing adds some back.

I'll post pictures when it's done.

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #3 – January 06, 2012, 08:47:23 pm

Thanks Dave, looking forward to the pics, and being that you are a musician

, your assessment of the sound!
Don

Quote from: Dave Katsuki – January 06, 2012, 03:02:43 am

As John says, it's pretty easy to remove the side panel, and what a difference in workspace!

I got resonator, flex pipe, elbows, pipe, reducer, clamps, etc., from Truck and Trailer Parts in Tucson (we are down in Benson now). Don't remember what brand the resonator is - probably Walker equivalent, and short. Tomorrow I will fab the hanger structure. I'll post pictures when done. And we will see how loud it is... I do know that the rig is much lighter on that side with the old muffler out! I'm guessing 80-100 lbs or so for the old muffler, but then the new resonator and plumbing adds some back.

I'll post pictures when it's done.

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #4 – January 08, 2012, 03:15:01 am

Finished the muffler replacement. Resonator installed, side back on. Tested it briefly, and it's not really much noisier at idle or with minor revving (haven't had it out on the road yet. I hear somewhat more hiss from enthusiastic exhaust gases leaving, but not at all bad. The test will be going through a tunnel under full power

Pictures follow. Didn't show the rearmost hangers that locate the tailpipe through the fiberglass, but they're there (mostly reused the old ones that I had added a while ago.)

The resonator is 10" in dia, and body is about 12-14" long (forgot to measure before I buttoned it up) so slightly larger than the short Walker.

I expect to have to re-tighten the clamps and brackets after it has been hot, but everything is so easy to reach from underneath now!

Body panel went back on in ~30 minutes. Next time would be less than 15 min (had to find some replacement screws). Definitely the only way to work on the exhaust!! I assume that the other side panels remove as easily, so that will make replacing shocks and air bags dramatically easier.

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #5 – January 08, 2012, 07:39:18 am

Howdy Dave, Nice Job!! Great pics!!! I can see this project in my future....
Dave Abel

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #6 – January 08, 2012, 10:11:14 am

Dave K, Congrats, now you have joined the gang of folks who are kicking their self in the rear for procrastinating so long over the resonator change.
I always laugh when another joined the gang of resonator dudes.
Enjoy like the rest of us are doing. By the way the Walker resonator is 20" overall length with a 12" body.
Cheers

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #7 – January 08, 2012, 10:58:37 am

Hi Dave K,
Thanks for the great write up! Pictures always tell the story.
Thanks again,

Raymond

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #8 – January 08, 2012, 12:20:38 pm

Nice job and nice pics! I cant wait to hear your final assesment of the sound and performence/milage improvements. I will definitely be doing a similar mod after i get through all of the "must dos".
Couple of questions though... The hangers you made look sturdy, but they appear to be mounted solidly to the frame, so the question is, is the flex tubing flexible enough to provide the necessary compliance as the engine moves? And, the last pic makes it appear that the tail pipe is on an upward slope. Are you concerned that condensation may collect in the low point, or is the piping stainless steel? And finally, what did you use for replacement screws? Did you upsize them or did they still tighten up?
Thanks, Don

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #9 – January 08, 2012, 12:33:32 pm

The only addition I would make ,is to call Jeg's or Summit Racing and get some header wrap, and place it on the pipe that is close to the condenser coil to keep the heat load off of it.

Nice job Dave.

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #10 – January 08, 2012, 01:40:21 pm

Dave, nice and neat and glad that my suggestion of removing the panel is finally being realised. It is very easy to do and makes the whole job easier. the other side is pretty much the same to get off. I would never hesitate about removing a panel to make life easier when trying to replace things and you can do so many more checks while they are off!!
John H

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #11 – January 08, 2012, 01:54:24 pm

I suppose the sides could be classified as cowling. JC

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #12 – January 08, 2012, 01:57:27 pm

Nice job Dave, taking side panel off sure makes it look alot easier to do. That mod is on my to do list also.

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #13 – January 08, 2012, 02:06:02 pm

Pierce can you hurry up and do this upgrade to your 6V92? Kent & I need to know if it's worthwhile!

PS Dave nice job and thanks for the pics!

see ya
ken

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #14 – January 08, 2012, 03:42:27 pm

Quote from: acousticart – January 08, 2012, 12:20:38 pm

Nice job and nice pics! I cant wait to hear your final assesment of the sound and performence/milage improvements. I will definitely be doing a similar mod after i get through all of the "must dos".
Couple of questions though... The hangers you made look sturdy, but they appear to be mounted solidly to the frame, so the question is, is the flex tubing flexible enough to provide the necessary compliance as the engine moves? And, the last pic makes it appear that the tail pipe is on an upward slope. Are you concerned that condensation may collect in the low point, or is the piping stainless steel? And finally, what did you use for replacement screws? Did you upsize them or did they still tighten up?
Thanks, Don

I actually wanted to have a little give in the mounting, so the supports are only mounted at the top. I'm now reconsidering that and may anchor the bottom of the inboard support angle to the engine cradle plate. The flex pipe should provide plenty of compliance for engine movement, since that's all there was for the old muffler. May also run a more vertical support (flexible hanger) down to the outboard end of the muffler so the muffler won't sag if the joints loosen (but if it does, it will just rest on the angle underneath. Always fun to design

And the pipe does have a low point just outboard of the muffler, but I'm expecting it to get plenty hot, so shouldn't be a problem. The rigid tubing and the muffler are all al-clad steel. Clamps, flex pipe and the final tip are stainless.
Decision was driven by what Truck and Trailer had in stock. When I get back East to visit my buddy with a TIG welder, I may redo it all in stainless, which would also be fun. Said it before, but I can't say it enough - working on the exhaust with the side panel off was really wonderful. No rust and grit in your eyes, lying on your back (to say nothing of the fun there would have been getting the old muffler out...)

Forgot to answer about the screws - I found flathead stainless screws (same size) in my collection and used them on the flange next to the rear compartment. Used the ones that were there to replace a couple of munged ones that were visible.

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #15 – January 08, 2012, 03:46:08 pm

Quote from: Bill Willett – January 08, 2012, 12:33:32 pm

The only addition I would make ,is to call Jeg's or Summit Racing and get some header wrap, and place it on the pipe that is close to the condenser coil to keep the heat load off of it.
Nice job Dave.

Thanks! Good idea to wrap the pipe next to the condenser! I've been planning to wrap the exhaust downstream from the turbo anyway, to reduce the heat in the engine compartment.

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #16 – January 08, 2012, 03:55:34 pm

It occurred to me as I was replacing the panel, that full body paint might make removal/replacement of the trim a little harder/messier. Maybe get Extreme to paint the trim separately? (We're planning to have our coach done at the end of the year.) Any thoughts from those who have full body paint? Hate to have to cut the paint at the joint to get things apart.

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #17 – January 08, 2012, 04:06:30 pm

Good answers! Be sure to let us know when you get a good road test in! Do I rember correctly that you have the VMSpc? If so and have you been using it to tracking exhaust temps, it will be very interesting to see what the differences are. Keep up the excellent moding, you are paving the way for those of us in the late 90's U270 land:)

Quote from: Dave Katsuki – January 08, 2012, 03:42:27 pm

I actually wanted to have a little give in the mounting, so the supports are only mounted at the top. I'm now reconsidering that and may anchor the bottom of the inboard support angle to the engine cradle plate. The flex pipe should provide plenty of compliance for engine movement, since that's all there was for the old muffler. May also run a more vertical support (flexible hanger) down to the outboard end of the muffler so the muffler won't sag if the joints loosen (but if it does, it will just rest on the angle underneath. Always fun to design

And the pipe does have a low point just outboard of the muffler, but I'm expecting it to get plenty hot, so shouldn't be a problem. The rigid tubing and the muffler are all al-clad steel. Clamps, flex pipe and the final tip are stainless.
Decision was driven by what Truck and Trailer had in stock. When I get back East to visit my buddy with a TIG welder, I may redo it all in stainless, which would also be fun. Said it before, but I can't say it enough - working on the exhaust with the side panel off was really wonderful. No rust and grit in your eyes, lying on your back (to say nothing of the fun there would have been getting the old muffler out...)

Forgot to answer about the screws - I found flathead stainless screws (same size) in my collection and used them on the flange next to the rear compartment. Used the ones that were there to replace a couple of munged ones that were visible.

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #18 – January 08, 2012, 04:11:14 pm

Dave,

Really nice job.

You might consider having Xtreme convert the two rear panels to hinged ones when in for the paint.

Early congrats on the paint.

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #19 – January 08, 2012, 04:14:58 pm

Dave K, I have been on Xtreme's butt about coming up with the hindged side panels like on the newer models, James & Rance seem to be interested, but no final work as of yet. Of course I have other projects for the fiberglass mods too, maybe I have them in overload.

Not a lot of mods left for my coach, just the hindged panels and new air intake for the engine are the two biggies I am interested in. Last one on the rear door mod is the best of em all I feel.
Dave M

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #20 – January 08, 2012, 04:26:01 pm

I'll be interested in the results of the intake mod.

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #21 – January 08, 2012, 05:05:10 pm

Quote from: acousticart – January 08, 2012, 04:06:30 pm

Good answers! Be sure to let us know when you get a good road test in! Do I rember correctly that you have the VMSpc? If so and have you been using it to tracking exhaust temps, it will be very interesting to see what the differences are. Keep up the excellent moding, you are paving the way for those of us in the late 90's U270 land:)

I do have a VMSpc, but it doesn't help with EGT. I installed an EGT gauge from Banks and watch it carefully on long uphills.
I welded the thermocouple boss into the pipe just after the turbo, and the Cummins guys said the turbo drops 300 deg, so I use a safe max as 1000 deg. Usually hit 900 deg on uphills. It will be interesting to see if that changes.

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #22 – January 08, 2012, 07:19:42 pm

Speaking of Xtreme's FBP, pulling the trim and rear panels would create a real mess IMO. You'd have to cut every seam, probably showing some white along the way.

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #23 – January 08, 2012, 10:57:37 pm

re-the full body paint and taking panels off, I have FBPaint and taking the panels off is not a concern, you just have to be a bit careful to line the joints up. I have done both sides and it still looks like they have not been off.
Re- the hinged panels for CAC access, if you look at my old pics, I installed the spring screw clips and nylon screws to hold it in place and it works fine at a lot less than having the hinge job!!!

Re: What did you do to your coach (Dave K's resonator upgrade) today.

Reply #24 – January 28, 2012, 03:47:25 am

Update on performance after the first 500 miles:

Noise:
A little louder (as expected), but no drone and surprisingly no noisier at highway cruising speeds. Very nice exhaust tone, in my opinion, especially under acceleration, but also some more hissing from the gas coming out faster. Inside with windows closed, no real change in noise. Very acceptable.

Power:
Definitely more power. I had planned to hold a steady 65 on the way back from Quartzsite to Benson, but got too excited with the additional power

, and was cruising at 70-75, passing trucks on long uphills, so I'm very pleased with the performance. EGT was a little lower under full load, and turbo spool-up is definitely faster. I did wrap the pipe after the turbo and also wrapped the long pipe to reduce heat load on the A/C condenser. (A/C performance was just fine.)

Incidentally, the local O'Reilley's auto parts store had header wrap, so there was no need to go to a speed shop or internet source.

Economy:
The flip side of my lead-foot driving was that fuel mileage was about the same, so I'll need more time at calm highway speeds to evaluate any changes there.

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