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GraphiteDak
GenIII
 
12/25/2005
00:17:45
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 Subject: Taking one for the team... again! :-)
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Many of you know I'm one to try something myself just for the experience, and to preove weather it works or not. (Some of my old mods I have reversed when they didn't do what I wanted).
Ok. The latest was the 4.56 gears. WORTH IT 100%
Well. My bro in law had taken the plunge hacking in some duals on his RAM egging me on to do mine (as I've TALKED about).
So. I bought some pipe. Some with some bends made into them for me. Some GLASS PACKS and assorted fittings.
Then last night I hacked my exhaust off, which by the way sounded damn GOOD with the Delta Flow 40 series.
I removed the stock y-pipe and welded in new pipe starting 2 inches off of the stock pipe at the manifolds. I went a little large I think. 2 1/2 inch all the way DUALS. The muffler shop said they use that size all the time on duals.
So when I get done, we will SEE if I lose any low end grunt. As I said, I enjoy experimenting and will report back what results i get.
My truck is a QC 4WD. A real BIATCH to get that drivers side pipe between the tranny and front drive shaft. But i did it. Cutting and welding the pipe to make short radius bends you can't make with a pipe bender.
So far I've got it routed to the dual cat converters I had to buy. I have more pipe to weld and then the Glasspacks. Then I will see if I can make the drivers side tail pipe that goes over the rear axle.
It should sound NICE with dual 2 1/2 all the way out the back.
Pix to come soon... Still working on it.
I'll upload what pix I took so far here in a bit.
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GraphiteDak
GenIII
12/25/2005
00:44:00
| RE: Taking one for the team... again! :-)
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OK. I'm goint to try to sopy and paste some HTML right from my web page to make this easy...
Dual Exhaust on the Dakota
Stock pipe. Dual 2 inch into single 2 1/2 inch
Hacking the sock exhaust off
The damn O2 Sensor wires pulled out of the molex connector...
Easy fix though.
I bought a few Cat Converters and some pre bent pipe to work
with.
Stock Y Pipe removed
This Y Pipe didn't look so bad to me compared to some.
With a mess, it's time to fabricate.
THAT is a tight fit! All custom short radius turns
I don't think I'll bother to grind my welds under here :P
A quick weld on this new hanger to get things in initial
position.
I will need to fabricate several hangers and supports once
everything is in place.
To be continued this week...
Maybe I will get more time to work on it tomorrow.
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Mopar318
GenII
12/25/2005
08:36:58
| RE: Taking one for the team... again! :-)
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Looks like this is gonna be a fun project. Just make sure you put an equalizer in there (X-pipe or H-pipe.)
BTW, will you be getting rid of your old flowmaster 40.
My rice eater
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Android287
GenIII
12/25/2005
10:31:30
| RE: Taking one for the team... again! :-)
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NICE!!!!
Nothing flows like a straight pipe
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Old Fool
Dodge Dakota
JOIN HERE
12/25/2005
10:41:06
| RE: Taking one for the team... again! :-)
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Well, I've done this project myself. I had the advantage of a 2 wheel drive truck which made this chore a bit easier. I routed mine different to keep the bends shorter. The original routing was dueled out the side, but it was so loud I couldn't here myself yell, so I went to the 3.5" super single routed out the back and turned down and hidden by the roll pan. gained 3/10ths in the 1/4 mile by going to true duals and or the Super single route.
Later,
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GraphiteDak
GenIII
12/25/2005
20:12:06
| RE: Taking one for the team... again! :-)
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Awesome Dude. 2WD and what looks to be a manual tranny, leaves you WAY more room than what I have! Glad you already busted the single vs. dual myth in loosing power!
That 5-45RFE tranny is a monster.
And the transfer case and front drive shaft really occupy precious space!
Right now my truck is apart still. At least I'm down to the tail pipes then to go back and add more hangers and weld any leaks :P
I'm having x-mas at the inlaws (fortunate enough to get on the neighbors wiresless with my laptop) so I think I may finish it tomorrow.
I'm running my tail pipes all the way to the rear so it wont be too loud inside the cab.
Plus I want that Glass Pack BARK when it raps out :)
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GraphiteDak
GenIII
12/25/2005
21:35:03
| RE: Taking one for the team... again! :-)
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Oh BTW. When I was cutting out the stock Cat it fell before I expected it to, and pulled the wires out of the molex connector. They just snapped back in though.
But when I started the truck after reconnecting it all I get a P0032 code, for the O2 sensor.
I wonder if one of the wire terminals broke in the O2 sensor side. Anyone ever TEST a O2 sensor?
Also, I only put the sensors on the right bank. My bro in law did the same to his RAM and no code. I figure it shouldn't make much difference.
OLD FOOL, how you got your sensors?
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NovaKarl
Dodge Dakota
JOIN HERE
12/26/2005
18:25:57
| RE: Taking one for the team... again! :-)
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I see you have a 4.7L 4x4...
I'm not sure what's available for your truck, but it looks like a lot of custom work.
Are those Magnaflow/carsound cats?
I have a 99 R/T, and about a year ago, the ceramic peice in my stock cat shattered, and ended up plugging the outlet of the cat.
I decided that if I was to replace the cat, I'd buy an aftermarket one, and if I was going to tear up my exhaust, might as well get some headers too.
I got the PPH headers, which have all this beautifully welded and bent piping that ends at the cat. The 99's don't have a y-pipe, they use a dual in - single out cat.
I ended up buying a cat with a 3" outlet and running 3" pipe back to a JBA EVOL cat-back exhaust system. The only "custom" work I had to do was to offset the pipes to get them to line up, and I brazed an O2 sensor bung into the pipe after the cat.
It felt like there was a performance gain, but it's hard to tell. It's pretty loud, and people tell me that my truck sounds like it's going to eat somebody. :D
Anyways, congatulations on doing this all yourself... it's a hell of a project to take on, especailly if you're doing a lot of fabrication.
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Old Fool
Dodge Dakota
JOIN HERE
12/26/2005
19:27:17
|  RE: Taking one for the team... again! :-)
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On my 4.7L it had the precats with the twin O2 sensors behind the precats, I left them there. Check casper Electronics for the O2 Sims, they are the most reasonable on price I have found for my customers.
O2 Sim for the 2000 to 2003 Square Single SIM
Later,
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GraphiteDak
GenIII
12/26/2005
21:35:00
| RE: Taking one for the team... again! :-)
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After I finished I messed with the wires trying to push them in better.
Reset the PCM using my SuperChips as a DTC scanner and the check engine light stayed out now. :)
I finished things up...
This was the only EASY part.
The 30" Glas Packs.
I had a REALLY hard time making accurate cuts with the sawzall and grinding wheel.
After this part I bought a chop saw today which I only used on the tail pipes...
No comments on the welding down here. That sh*t was buring the pi$$ out of me. Even though I have a auto darkening helmet and gloves. It burnt my hair, neck, everywhere a spark could go!
So I had to stop and start a lot and I refuse to take the risk of running the Grinder under there to make welds look pretty.
Now look at this part. I criss crossed the exhaust as they go over the axle. Now the driver side exits on the passenger side and vise versa. This makes the pipes even length.
I used a clamp here and there. Most parts welded together in as long of a section as I could install at once. Theh clamped at a few places.
Sound clip http://www.paysonarizona.net/mp3's/Dak_122605_Duals_revSoundSample_03.mp2
Video Clips in Real Player format
Video 1
Video 2
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Android287
GenIII
12/26/2005
23:49:58
| RE: Taking one for the team... again! :-)
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Message:
Well???? Does it feel like you gained some power?
Nothing flows like a straight pipe
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GraphiteDak
GenIII
12/27/2005
00:01:24
| RE: Taking one for the team... again! :-)
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I would really need to go to the track to see evidence of power lost/gained.
However. I did notice one thing.
Before the duals, my power ran to a screeching hault at 6200 RPM's and slowly climbed to 6500 limiter.
Now it seems to pull all the way to 6500.
If I were to do anything else to the truck, I would think I should go one or two steps over the HO cams. As long as I can do so with my PCM I have now, which I don't know why I couldn't.
With the ability to breath a littl better the more agressive cams would open up HP at the higher RPM's. With the 4.56 gears I would not miss the 2000 and below power.
The truck is sure LOUDER on the throttle than before. I went to Wal Mart. Hit the gas just enough to make it bark. A woman grabbed her kid and jumped. Even though I wasn't that close to them. It struck fear. And that's all that counts 
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FLDak
Dodge Dakota
JOIN HERE
12/27/2005
11:55:35
| RE: Taking one for the team... again! :-)
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Message:
Good Job!!
I used Thefastman o2 simms on mine because I got rid of the dual precats.
The only thing I would suggest doing different is put a x-pipe in there.
Yeah it will definatly breath better now, good idea on the tailpipe criss cross. You're stock y-pipe was not as bad as others I've seen. You'll be glad you got rid of it none the less.
Now if someone only made long tube headers for our 4.7L engines I would be finished with my exhaust.
Once again good job, later...
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Kowalski
GenIII
12/27/2005
17:02:46
| RE: Taking one for the team... again! :-)
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Hotter cams love lower gears - go for it !
Lead, follow, or get out of the way
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GraphiteDak
GenIII
12/27/2005
21:32:25
| RE: Taking one for the team... again! :-)
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Yeah long headers would be awesome.
Some day, I may get carried away and MAKE some!
kowalski, that is exactly what I was thinking.
Tonight we just went to the store and back. The wife is NOT Happy with the decibels of my exhaust. She is MAD I removed the Flowmaster for the Glass Packs.
One problem I have is that behind my rear seats where my subs are, I pushed out them vent thingies and cut out the insulation. I think some noise comes in there.
I think I'll mod a new vent in between the seats (must be there to relase pressure when the door closes). I also need to get some of that bubble looking foil type insulation and I'll glue it to the metal behind my cab on the OUTSIDE and under the truck in a few places. That should drastically reduce in cab noise. That stock insulation under my cab is loose since I went through creek crossings and the likes.
All in all. I'd hate to get rid of the glass packs. The truck is very loud now when I give it throttle. It set off alarms very easily tonight in a parking lot. Some people walking actually JUMP when I goose the throttle some :)
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Kowalski
GenIII
12/29/2005
16:08:29
| RE: Taking one for the team... again! :-)
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Yeah, I figured you were already thinking that !
Around here there's a roofing product generically called "bituthane" used mainly to prevent ice damming, so I don't know if you've seen anything like it in your area. 3' roll of almost 1/8" rubbery stuff with an adhesive backing, just peel the paper off the back to stick. Makes great sound deadening material for vehicles if you can get your hands on something like that, stick it to any metal panel under the carpet or upholstery. Good luck appeasing your wife !
Lead, follow, or get out of the way
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jpkomm
Dodge Dakota
JOIN HERE
12/29/2005
17:17:35
| RE: Taking one for the team... again! :-)
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Dang, Graphite! You're gonna give an old man a heart attack if you keep goosin' your engine at Walmart. ;) Makes me feel a bit meek about getting a "half a$$" dual exhaust. May just stick with a single till I can afford to go all out.
On your original Delta Flow 40 Flowmaster, was it an offset in/center out?
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GraphiteDak
GenIII
12/29/2005
22:57:29
| RE: Taking one for the team... again! :-)
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Old Delta Flow was center in/out 3" reduced to 2 1/2
I'll look around Kowalksi. I did some work on it this afternoon. Maybe post pix later of more butchery to my precious Dak!
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Redfelt
Dodge Dakota
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1/04/2006
14:25:38
|  RE: Taking one for the team... again! :-)
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Quick question, the O2 sensors that poped out of the connector, you said quick fix...how does one do it and can it be done on factory sensors. I tried to disconnect the sensors electrically and snapped the plastic pin, I cannot see how it comes apart.
can you help
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DSW
Dodge Dakota
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1/04/2006
15:27:44
| RE: Taking one for the team... again! :-)
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Hey Graphite, Noticed your air-bags in one of the pic's. The setup looks pretty good! Where did you get the kit, who made it, was it a universal kit and what was the $$$... Sorry if I asked this before ;-)
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GraphiteDak
GenIII
1/04/2006
17:11:40
| RE: Taking one for the team... again! :-)
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Redfelt, the sensor was a real BIATCH to get apart at the connector. Even after breaking the clip off myself. I spent a good 30 minutes cursing at the thing! I could tell MUD had been packed into it from my old offroading days.
Keep prying on it by shoving screwdrivers in between to loosen it.
DSW. They are Firestone air bags. Were over $300 bud made for DODGE rear setup. They pretty much fit as they came with minimal tweeking.
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