53 willys

Here is a little DIY on how I did my 5" turbo back exhaust to a 7" single miter stack.

first yank the stock set-up...I used my trusty porta-band saw

here is a shot of what I started with.

10Ft of 5" pipe.

12" of 5" flex

90* elbow...5"ID-5"OD......9.5"x9.5"

5"ID x 5"ID connector... 8" long


Next I set up the 5" turbo down pipe that I scored in the DTR classifieds...
I welded 5"ID x 5"ID connector... 8" long to the turbo down pipe so that I could attach the straight 5" (10ft) pipe..

next was stack set-up...you need to get everything leveled/plumb so you can mark the stack hole and the mounting bracket.....

then mark the bed where the stack would go through...

53 willys

My stack ended up going through the floor on the 3rd full length bed rib as seen below.

here is the homemade stack clamp I came up with while the 7" Staxx Clamp I want is being made...



bracket holes and bed hole marked with a white sharpy..

Next I slide the 10ft section of pipe under the truck and connected it to the turbo-down pipe..then I made sure the hole I marked in the bed matched where the pipe was under the bed!!!
now it is time for the HOLE!!! I bought a 5" hole saw for mine...BTW cutting fluid is your freind

]I wanted my stack as close to the bed front/cab as possible, witch meant I had to drill into the bed support...no big deal.

VaultRam

Sweet....so far so good. Cant wait to see the final product. I've been waiting a long time to see this write-up

jrussell

Awesome write-up and pics!!!

I want one soooo bad but don't want to slide my toolbox forward and lose the bed space. Make sure to get a video of the sound! I'm curious to know how loud it is inside the cab?

53 willys

I decided to keep my cat as to stay legal so to do that I needed a 5" cat so I decided to turn my stock cat into a 5" cat by cutting the ends off
with the trusty porta-band...

Got restriction???? this was held up strait to the sun and this is all the light that would shine through



Next I wanted to have the cat as close to the stack as possible (hoping it would give it a deep sound) so I welded it right to the 90*elbow...

then I cut a small 4" long piece of 6" from the 10 footer and welded it to the flex pipe...


Then I welded that to the cat too...
once I had that ready I was able to measure how much of the 10 footer I needed to cut off..
after I got the 10 footer cut I mocked the whole setup in the truck to make sure it fit.. sorry forgot to get pics of the mock up.
then I pulled it all back out and painted it with some 1200* flat black paint and the stack was sprayed with some 500* gloss black and clear...I also had to by a third clamp...

53 willys

I finished the hole off with some trim I had from some other projects...this stuff is pretty handy





It got to dark to take pics last night...I started at 11:00am and was done by 9:00pm..yeah it was a pretty long install but the painting takes a lot of time
finished pics are coming in a few...................

HotRodK

WOW! Nice write up and photos. I cant wait to see it!

goodeyesniper75

where did you get the stack from?

53 willys

it's a unfinished Grand Rock stack that I bought from one of their dealers
oops I forgot to put that part in there
PM me if you want the place I bought from

53 willys

Ok I am going to snap some pics and and do a sound clip, stay tunned..................

53 willys

Also I welded a 15" piece of 6" onto the stack so that all my clamps where under the bed out of sight

goodeyesniper75

what paint did u use on the stacks?

Pitz

Sweet -- nice job!
Where did you find the pipe/fittings?

53 willys

500* gloss black engine enamel and 500* engine enamel clear coat..from any parts store.

but don't go out and buy it yet cause I don't know if it can handle the heat yet???

I will show you why in an hour or so when I get the pics taken......

Jeff K

500* paint should be more than enough for the stack. The problem I have always had with paint on aluminized exhaust is that it just doesn't stick very well for some reason.