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1994 K3500 extended cab dually

ak diesel driver said:
How similar is that to the military version?
Click to expand...
Pretty different. I didn’t like how number 5 cylinder was done on the Hummer headers, plus I wanted v-band flanges and I wanted to control the routing of the crossover, so for those reasons I decided to make my own. Ironically, I also don’t love how I did number 5 on mine, ha.

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@n8in8or

Could you post a pic of how those flanges fit on the head around the glows and other humps on the mounting surface?

Another question sense you are in the area, if a person used 1 1/4 diameter sch 10 ss pipe and connected 2 cylinders into 1 pipe, do you see room to have 2 crossover tubes, say 1 1/2 diameter ? That way maybe get better use of the firing order ?
 
Twisted Steel Performance said:
@n8in8or

Could you post a pic of how those flanges fit on the head around the glows and other humps on the mounting surface?

Another question sense you are in the area, if a person used 1 1/4 diameter sch 10 ss pipe and connected 2 cylinders into 1 pipe, do you see room to have 2 crossover tubes, say 1 1/2 diameter ? That way maybe get better use of the firing order ?
Click to expand...
Yes, I can definitely get you some better shots of that for you. I should be able to this evening.

I don't see any reason why dual crossovers couldn't be done. I was mindful of the firing order on the turbo side, making sure 2&4 were on one half of the turbine and 6&8 were on the other side of the turbine. I also attempted to pair 1&3 and 5&7 on the driver side, but I compromised those pairings so I could get the tubes in the space I wanted. I hadn't thought about dual crossovers for a sidewinder.....that's an interesting idea. That would have made construction of the driver side easier.
 
Twisted Steel Performance said:
@n8in8or

Could you post a pic of how those flanges fit on the head around the glows and other humps on the mounting surface?

Another question sense you are in the area, if a person used 1 1/4 diameter sch 10 ss pipe and connected 2 cylinders into 1 pipe, do you see room to have 2 crossover tubes, say 1 1/2 diameter ? That way maybe get better use of the firing order ?
Click to expand...
Here are some pics. This flange is one I had made for me locally that was a copy of the ones you can get online.

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It could use a little touch up with a grinder to get it to align properly.

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Will L. said:
All this other nonsense stuff like steering and brakes on the way of exhaust… just not right!

That should help a good chunk, definitely need a flex in there for expansion under heat.
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Yeah, when Chris asked about flexes, that was a “DUH” moment for me - especially since the crossover is going to be stainless. That’s why these threads are the best - you smart guys catch me before I make a mistake.
 
Last night I started cleaning up the inside of the driver side manifold. I was working on the collector and I wasn’t happy with how the #1 tube merged. I had put a radius there when fabricating the header, but the final result wasn’t great and unfortunately ended with a right angle for the inside radius. I had build it up a little with weld that I could grind away, but I just wasn’t happy with how it was turning out.

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So tonight I started by cutting that section out and fitting a section of inside radius in. Much better now.

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The ports are cleaned up as well.

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I also added a bung so I can measure pressure in this manifold and compare it to the turbo side. I did this because I’m doing a 2” diameter crossover. I THINK 2” is going to be big enough and make sure I have good exhaust velocity to the turbo, but if I find that the pressure is higher on the driver side, then I’ll know that I screwed up and need to make a larger crossover.

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On your flange, that arched section connecting to the next port almost looks as if it might make things harder to work around the GP's. wonder if once the headers are done, you could cut each section out so each port is separated? the flange is good n flat in those area so you could also install studs in the head and not have issues removing the headers for future work too!
 
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