Resonator and muffler replacement

Topic: Resonator and muffler replacement (Read 12582 times) previous topic - next topic

Re: Resonator and muffler replacement

Reply #225 – August 31, 2015, 01:55:57 pm

Noticed lower exhaust temp and better throttle response with previous coach, 8.3 mechanical with Banks kit

Re: Resonator and muffler replacement

Reply #226 – September 01, 2015, 04:42:16 pm

Well, this recent chatter about exhaust mods provided the push I needed to get off my.....rear....and finally start my own project. Got half of it done today (the hard part) - will finish after I get a few parts. I think all I will need is a 4" 90 degree bend to go between the down pipe and the muffler, and a 4" to 5" adapter to connect muffler to exhaust pipe, plus a couple clamps. I'm going to try to modify the OEM muffler hangers to work with the new muffler. More photos in a couple days.

Re: Resonator and muffler replacement

Reply #227 – September 01, 2015, 05:02:10 pm

Quote from: Chuck & Jeannie – September 01, 2015, 04:42:16 pm

Well, this recent chatter about exhaust mods provided the push I needed to get off my.....rear....and finally start my own project. Got half of it done today (the hard part) - will finish after I get a few parts. I think all I will need is a 4" 90 degree bend to go between the down pipe and the muffler, and a 4"to 5" adapter to connect muffler to exhaust pipe, plus a couple clamps. I'm going to try to modify the OEM muffler hangers to work with the new muffler. More photos in a couple days.

Chuck...

3rd pic looks like Mama with a "little one"

Hans

Re: Resonator and muffler replacement

Reply #228 – September 01, 2015, 05:15:22 pm

Quote from: Chuck & Jeannie – September 01, 2015, 04:42:16 pm

Well, this recent chatter about exhaust mods provided the push I needed to get off my.....rear....and finally start my own project. Got half of it done today (the hard part) - will finish after I get a few parts. I think all I will need is a 4" 90 degree bend to go between the down pipe and the muffler, and a 4"to 5" adapter to connect muffler to exhaust pipe, plus a couple clamps. I'm going to try to modify the OEM muffler hangers to work with the new muffler. More photos in a couple days.

Good luck re-using the mounts. I was not so lucky...I tried to re-use them and thought i did a pretty good job but it wasn't up to the tasks (they ended up sagging and the resonator was bouncing around). IMHO I would save yourself the headache and just start from new mounting hardware.

Re: Resonator and muffler replacement

Reply #229 – September 01, 2015, 06:13:42 pm

Jeff,

Since you have a "Cat", your exhaust system may be suspended differently than mine. You can see my OEM hangers in my 5th photo above. They are 2 flexible steel straps that hang down from a rubber mounted heavy duty steel bracket. Since they supported the original muffler for 22 years, I am sure they are strong enough to hold up the new one. I just need to cut the straps at one end and shorten them sufficiently to fit the smaller muffler, then reattach the end pieces. I'll give it a try, anyhoo...if it don't work, there's always plan "B".

Re: Resonator and muffler replacement

Reply #230 – September 01, 2015, 06:31:33 pm

Chuck we have the same configuration I went to plan b

Re: Resonator and muffler replacement

Reply #231 – September 01, 2015, 07:02:16 pm

Looks good Chuck, I think you are going to like it. We just came over I 80 west bound and went over the sisters a really long steep climb and really like the little extra power and when we got here to park city the bedroom was a lot cooler. Good Luck on your project.

Re: Resonator and muffler replacement

Reply #232 – September 01, 2015, 08:33:06 pm

Quote from: Doug Weil – September 01, 2015, 06:31:33 pm

...I went to plan B.

That looks pretty sanitary. If my idea doesn't pan out, I could do similar...in fact, I already have several of those hangers from a prior hotrod project. Thanks!

Re: Resonator and muffler replacement

Reply #233 – September 01, 2015, 08:43:02 pm

Thanks to your post, I just noticed I have a broken hanger, In a picture that I hadn't posted. Can't even blame it on a washboard road south of the border!

Edit: after a closer look this hanger turned out to be one with a hook instead of a pass through, it's been a few years since install.

Re: Resonator and muffler replacement

Reply #234 – September 01, 2015, 08:48:56 pm

Craig,

I've read articles in the Turbo Diesel Register that showed no improvement in performance going larger than 3" dia. with the 5.9.

Re: Resonator and muffler replacement

Reply #235 – September 01, 2015, 09:18:00 pm

Quote from: amos.harrison – September 01, 2015, 08:48:56 pm

Craig,

I've read articles in the Turbo Diesel Register that showed no improvement in performance going larger than 3" dia. with the 5.9.

Ok... I suspected that, anyway. 3" it is!

Craig

Re: Resonator and muffler replacement

Reply #236 – September 01, 2015, 09:33:48 pm

Craig, 4 inch straight front to back with a k&n filter, sounds good! and yes I carry a paper filter also... a little Baja teaser.

Re: Resonator and muffler replacement

Reply #237 – September 04, 2015, 10:35:15 pm

Finished my muffler install today. I'm real happy with the result. The muscle aches, joint pain and stiffness will wear off, eventually...

Things went together pretty much like I planned. I reused the tailpipe, and it ended up sticking out 1" further than before. It is now perfectly centered in the fiberglass cutout - before it was resting on (being supported by) the edge of the hole. For my installation (besides the muffler), I only had to purchase one 4" 90 degree angle, and one 4" to 5" adapter, plus a couple clamps. I reused 3 clamps and the short piece of stainless flex pipe. I scavenged the rubber pieces out of some extra exhaust hangers I had on hand. At the front of the muffler, I made two supports that attach to the clamp bolts. At the rear, I reused one of the old muffler support straps, but modified it to fit the smaller muffler. The tailpipe was still a little "loose" feeling, so I added a turnbuckle to limit the movement. The tailpipe can move, but it won't hit the edges of the hole.

Fired up the big engine, but I couldn't hear much difference. I don't think its any louder, at least at idle. The real test will come when we take it for a spin. Can't wait!

Re: Resonator and muffler replacement

Reply #238 – September 04, 2015, 11:03:43 pm

Looks good Chuck, you're confident it's not too close to the coach floor. I know the old one was up there but that had more surface area to dissipate the heat...

Re: Resonator and muffler replacement

Reply #239 – September 04, 2015, 11:26:01 pm

Looking at pictures I would guess it is about 8-10" down from floor. Lots of room.
JohnH

Re: Resonator and muffler replacement

Reply #240 – September 04, 2015, 11:55:10 pm

Quote from: Doug Weil – September 04, 2015, 11:03:43 pm

...not too close to the coach floor...

Yes, John is correct - the photo angle makes it look a lot closer to the floor than it actually is. There is much more room above the new muffler than there was with the old one. Look at my earlier photos, where I had the new muffler laying on the ground next to the old one. The old muffler was actually touching the "C" channel iron mounting bar. You can see the rust marks on the top of the case. The new muffler is suspended several inches below the bar at the same height as the the inlet of the old muffler, which was in the center of the case. Airflow around the new muffler should also be much improved.

Re: Resonator and muffler replacement

Reply #241 – September 05, 2015, 08:10:37 am

Looks as good or better than pics of berndts installs... and it probably cost you a coach buck less or so. =)

win-win!

Re: Resonator and muffler replacement

Reply #242 – September 05, 2015, 08:23:16 am

Matt I agree with that statement, the only thing based on my experience he saved more than 1 coach buck doing himself.

Re: Resonator and muffler replacement

Reply #243 – September 05, 2015, 09:40:43 am

Money isn't everything, but I don't mind saving it when possible. Then I can spend it elsewhere! In case anyone is keeping score, my cash outlay for this project is as follows:

Magnaflow 12771 (from Amazon Prime, free shipping) $123.00
4" short 90 elbow, 4" to 5" adapter, 2 clamps (local truck supply) $ 61.17
Various small bits of hardware from personal cache, + Labor $ FREE
Reclining under the coach for most of 2 days in 90 degree heat PRICELESS

Re: Resonator and muffler replacement

Reply #244 – September 05, 2015, 10:47:21 am

Well done Chuck, and I will say it again , you do NOT have to take your coach to any shop to do this change, unless of course there are physical constraints with ones body( or you have too much money). I am slowly getting to know what that feels like too!!
JohnH

Re: Resonator and muffler replacement

Reply #245 – September 05, 2015, 11:42:38 am

Great job Chuck- you will really like the difference on the road.

John H.- I agree that he saved a lot by doing it himself. There are some of us on this forum who have much less mechanical skills, tools, and a place to work on a coach ( full time on the road) , so we have to rely on someone else to do it. The real shame is that we don't have too much $$$, but would like to have the ability to team up with those who have a shop, pit, tools, etc, to do projects and get advice on how to do these things. I would be very happy to share $$$, meals, liquid refreshments, etc in order to do regular maintenance with someone who has gone there before.

Hope to see you at Quartzite again- this year no problems................

Re: Resonator and muffler replacement

Reply #246 – September 05, 2015, 12:24:31 pm

Quote from: Chuck & Jeannie – September 04, 2015, 11:55:10 pm

Yes, John is correct - the photo angle makes it look a lot closer to the floor than it actually is. There is much more room above the new muffler than there was with the old one. Look at my earlier photos, where I had the new muffler laying on the ground next to the old one. The old muffler was actually touching the "C" channel iron mounting bar. You can see the rust marks on the top of the case. The new muffler is suspended several inches below the bar at the same height as the the inlet of the old muffler, which was in the center of the case. Airflow around the new muffler should also be much improved.

Yep, pictures look a little deceiving expescially on my 2.5 x 4 inch samsung screen

Re: Resonator and muffler replacement

Reply #247 – September 05, 2015, 03:12:16 pm

Looks great Chuck!! It's been about 9 months since my switch and I didn't notice much performance improvement and my MPH is about the same (10.5-10.

. The only noise difference the DW noticed (my hearing isn't that great so I'm not a good judge) was when next to a cement barrier she thought it was a "little louder". I just thought it was a little throatier...Its a good DIY project

Re: Resonator and muffler replacement

Reply #248 – September 05, 2015, 04:53:03 pm

Ted and karen, if anyone wanted to come this way they are welcome to do so and can use the pit and my help anytime. No one wants to come here even though they are missing one of the best places on earth to be. we have the space for another coach and 30amp hook up, so, any time (as long as we are here of course)
We will most probably not make it this winter as we will be doing an around US trip then down to Mexico again end of Dec.
Yes, no more problems for sure.
JohnH

Re: Resonator and muffler replacement

Reply #249 – September 07, 2015, 01:10:12 pm

Well done. You will love it.

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