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New Years WE, Part2 - Exhaust system replacement

Gulfsurfer

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More fun over the weekend: The restricted stock system had to go. I ordered a mandrel bent Diamondeye system which consisted of a 3" down pipe connecting to a 4" series of pipes to the rear with a SS muffler (no cat converter).

I can't say enough good things about this package. It is well made, the bends are carefully thought out. I did not use the normal clamps that came with it though, decided to use the TorcTite band type (?) clamps from NAPA to facilitate system modification or repair later.


2Exh1a.jpg

The pic above shows the new crossover installed. I ordered the 2-1/2" crossover pipe from Warpspeed. Once again, great workmanship, complete package. It came with all new studs and nuts, I only had to use one of the studs. I was spared most of the headaches I've read about. No broken studs, the flanges are drilled out so that they were easy to install. The center to center distance matched up within 1/8"! I could have done this job in 30 minutes. All I needed to buy were two donuts from NAPA.


2Exh3.jpg 2Exh3a.jpg 2Exh5.jpg

Pics above: Left - Does the old intermediate pipe on the right look restricted? Middle - downpipe installed, perfect fit Right - The new 4" intermediate pipe connects to the 3" downpipe with a well thoughout reducing bell joint.


2Exh6.jpg

The system installed looking towards the rear. The old style clamps were only used where a support was needed to the stock rubber hangers. These clamps are not deforming any of the slip fit joints. The slip fit joints are being secured by band clamps.


2Exh6a.jpg 2Exh7.jpg 2Exh8.jpg

Pics above: The installion of the over-axle portion took most of the system install time. I had to make sure there was enough clearance for 6" or so of xle travel. Left - Luna, my Catahoula yard dog, oversaw most of my work. You can see the relative difference in pipe diameters in the background. Middle - over-axle portion looking from rear to front Right - the only hanger I had to modify was the rear muffler hanger. Heat it up with the oxycetylene and bend it forward 3" to match the existing hanger mount.


2Exh8a.jpg 2Exh9.jpg

Pics above: Band type clamp I used, from NAPA, I used 4 of them at about $12 a piece.

The business end of the exhaust. Really breathes freely, turbo spins up much quicker as expected. It's got a nice rumble at idle now. Gets louder as I put my foot into the pedal. It's not too loud pulling a small enclosed utility trailer (maybe 2k#). We'll see how loud it is pulling my 10K# boat. I may have to swap out the muffler for something quieter if the wife and kids complain.

Next thread: remove vac pump as part of the Turbo master install.
 
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Fantastic write up! Thanks for sharing. This is exact setup I'm looking at for both Suburban and Tahoe. I am now convinced it will work with the Sub. Can you tell me which band clamps you purchased? It looks like you got the 'reducing' type? Got any part numbers?

Also, did the muffler come with the DiamondEye system?

Thanks so much.

-Rob :)
 
...welcome! I'll get you NAPA C/Ns for the "lap-type band clamps" (reducing) tonite.

The DiamondEye system was complete except for these better clamps.


Fantastic write up! Thanks for sharing. This is exact setup I'm looking at for both Suburban and Tahoe. I am now convinced it will work with the Sub. Can you tell me which band clamps you purchased? It looks like you got the 'reducing' type? Got any part numbers?

Also, did the muffler come with the DiamondEye system?

Thanks so much.

-Rob :)
 
TorcTite C/Ns

The NAPA C/Ns for the TorcTite clamps is BK733-3224, cost was $12.69 per.

They are what I would call Lap-Type, where one pipe fits inside of another. The other type, not needed for this system install would be a Butt-Type where both pipes are the same diameter and fit together.


Fantastic write up! Thanks for sharing. This is exact setup I'm looking at for both Suburban and Tahoe. I am now convinced it will work with the Sub. Can you tell me which band clamps you purchased? It looks like you got the 'reducing' type? Got any part numbers?

Also, did the muffler come with the DiamondEye system?

Thanks so much.

-Rob :)
 
not a warpspeed crossover!

I just realized that the crossover I installed was probably not a Warpspeed but a unit I bought of an eBay seller (muffler-house). It sat in my garge for about a month and I had forgotten where I got it (early-Oldtimer's disease setting in?).

It still was a good product for a good price. Fit perfectly and came with all new hardware.

See the listing pic below, it even has a part number (19410) that may let you figure out who makes it:

Sub-crossover.jpg

By the way, the DE exhaust is too loud even with the muffler. I'm looking at a Walker Big truck Muffler 21471 to tame the bark & drone. I know...I'm a wuss...just don't like it that my Sub sounds as loud as the garbage truck that comes by once a week. Also, wifey says it's embarassing when she has to use it to pick up my daughter from school whle her mom-mobile minivan is broke down in the driveway. :rolleyes5: I've got to fix that thing and get her out of my towmobile.
 
crossover $78 shipped

DE system - approx $300-350 IIRC. I ordered it over the phone from Treasure Valley Diesel, don't have the paperwork handy. I'm glad I did because their eBay listing made me think I needed one kit but I really needed a different kit. I seem to remember that the Sub and Pickup kits were different but the listing wasn't explicit about that.


if you don't mind telling - how much did the crossover cost and how much did the exhaust system cost?
 
I got my Diamond Eye (warpspeed) exhaust from Ebay(click me)

I got it in 2 days for 299$ and an extra 20$ for the SS Tip (PBRAC5012-4SS) which he shipped for free also with the exhaust ( Dropped Shipped)
BYMMV :smile5: also found the OP's clamps on amazon for about 10$ each.
 
Yep me too. The band clamps will strech some to take up the diff and the are a little cheaper.

Either way will work. Looks great Gulf!!!

thx, followup thread coming. Just ordered the Walker 21471 BTM from RockAuto (5% discount code: 26131852166321 :thumbsup: ). 27" shell length vs 20" (Diamond Eye glasspack). It's still a straight thru design, shouldn't affect performance too much, hoping it's quieter than the muffler the DE system comes with.
 
I got my Diamond Eye (warpspeed) exhaust from Ebay(click me)

I got it in 2 days for 299$ and an extra 20$ for the SS Tip (PBRAC5012-4SS) which he shipped for free also with the exhaust ( Dropped Shipped)
BYMMV :smile5: also found the OP's clamps on amazon for about 10$ each.

I clicked on the link and after a few emails from the ebay seller, they told me that they are up and coming and do carry stainless steel kits, crossovers and kits without the muffler as well. May have to contact them via email or phone to get a list of all their items. Real nice to talk too and they even sent me the part # for kit I need for my Yukon.
 
Great job on the exhaust:thumbsup:. I do like the clamps you used. They use them on alot of big trucks. The only problem till they get hot they sometimes leak ( smell diesel ).
 
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