Will some body please help turn me on to a reasonable place to order a 3.5 inch exhaust system for my 93 extended cab D250 2wd 5.9 Cummins. Also I would like the down pipe , air filter and turbine exhaust shroud up grades along with gauges. I have looked around and found little. Please help me. :-[ Thanks

 

A cheap alternative to a four or five inch exhaust is buy straight hard pipe, flexible pipe from Kenworth, Freightliner or big truck part supplier, and band clamps.

All the big rigs use flex pipe for the bends, so why not use it on your truck. I used flex pipe around the transfer case and band clamped a 6 1/2' straight pipe to the rear axle. A 4' piece fit very nice over the rear axle to the rear corner for exiting. Galvinized pipe is $3.00 a foot and Stainless Steel runs $8.00 --- $12.00 a foot. I used galvinized first to experiment first.

I made a 45 degree hard pipe turn at my work. But, any big truck muffler shop can make pieces like that for ten to twenty dollars. They made me a reducer from 3" to 4" for $10.00!!!

Also, check out big truck junk yards!!! You'll find exhaust pipe, combo gauges, pyro gauges with thermocouples, chrome goodies, mud flaps, etc. etc. Save yourself money and shop around big truck shops and junk yards...

The total project list:
5 4" band clamps
3" to 4" reducer
2' 4" flexible exhaust pipe(around transfer case)
6 1/2-7' straight pipe
4' 4" flex pipe over the axle
1 45 degree turn
1 home made exhaust tip (cut from the same 4" pipe)

LESS THAN $100.00!!!!!!!

 

I also made my own. Tommy is right, you can get plenty from truck shops. I made a full 4" system. I bought a dynomax muffler for about $70 and it was straight through. It still has a good deep sound but is somewhat quieter than straight pipe.
The truck shops that sell the "mid size" trucks will have 4" the big truck shops usally have 5".
A 10' piece of straight 4" cost about $40 at the local IHC dealer.
I dont know if you do any welding but I pieced mine together and it is all mandrel bent preformed elbows.
Good luck. ;D

 

Frostie and Tommy are correct. I bought all of my stack parts straight from Freightliner. Just be sure and go with stainless flex pipe if you use it. You will pay more, but you will only have to be in there once.

If you dont want to fab your own setup. Rip Rook has a nice system for the 1st gens
http://www.protintnw.com/sa-main.htm

For your gauges and other goodies, http://www.wildcatdiesel.com is my first choice. http://www.piersdiesel.com also caters to the first gen crowd.

 

Hey Tommy, Frostie and Monty, thanks for the insight, you know, I never thought of making my own, and the price is right since some kits that I have seen are on towards the $500 mark. I still need to go get the turbine shroud and the K&N kit. Does the shroud really make that much difference, and should I still stick with the non wastegated one? I'm not going to all the way on this machine, but I am lookin to make it run right. Also Monty, I printed your section on adjusting the first gen pumps, thanks. I'll let you know how the pump and exhaust work out.

 

dana70, when you say exhaust shroud, do you mean the exhaust turbo housing? The best all around housing for towing and running around is the 16. That is, if you plan on getting wild with the mods, pump tuned, injectors etc. IMO And, it can be had just about anywhere for around 150 bucks. A 92 model will notice more response going to the 16 than a 93 model, because the89-91.5, 93's was smaller than the 92's to begin with. Increased off the line spoolup is noticed and mine made the truck feel like it was easier to maintain a set speed.

 

dana70;
The Bully Dog exauast, sold by ADT "link here on DTR" is a really desent set up at $299.00. It comes with enough pipe to run striaght pipe or their luverflow 4" mufler,3"-4"adapter & 3.5"-4" adapter, for your down pipe conection, Clamps and hangers also. The design does keep the soot of your truck ;D ;D Like they claim. I'm very happy with mine.
Doug & Dawn are good folks to work with also. ;D

ramguy