DIY Exhaust - Cutting Tubing

[BIGglaSS]

I have $677 in materials for my stainless 2.5" mandrel bent dual exhaust. With Magnaflow mufflers and dual catalytic converters. I'm pretty sure if I dropped it off at a shop, the bill would be double that.

[1project2many]

Originally Posted by Matt_50

I've been watching this thread. I plan to use my donors exhaust and I think I just need to shorten it. One cut and weld it up... wish me luck lol.

Are there any rules of thumb for exhaust clearance? Distance from cab, frame, rear axle, and the bottom of the wood bed? Should I get or use heat shields for the bed and under cab where the gas tank is?

Good luck! Shielding depends on how hot the exhaust will get and how close it runs to tank & other stuff. Under the tank, if the pipes are 2-3" away, it's definitely a good idea. Near starter wires or starter, or near master cylinder, 3-4" is nice if you can get it. Otherwise shielding is a good idea.

It's rare to hear someone say they have to remove an exhaust shield because parts are not heating up enough.

Also, to the OP, I was taught to cut pipe with a hack saw by a pipefitter from a paper mill. Paper slurry will build up and plug a pipe in a hurry if the joints aren't perfect. The trick to good cuts and joints that fil together well is to use a good pattern and to cut small sections at a time with the saw. A band of paper taped to the pipe, wrapped around, and taped back to itself serves as a guide. Cut a little, turn the pipe, cut again. Works well.

[b-mac]

Thanks for all the info guys. And a tool I've never seen before.

I'm definitely going to try it.

[b-mac]

Ok, one more question.

S10 swap build. I kept the stock transmission cross member (narrowed). But then decided on a 4link, and moved the tank to the rear.

For simplicity sake, do I build a new cross member to run straight duals, or snake around to the passengers side, then back across for split exhaust?

[_Ogre]

Originally Posted by Matt_50

I've been watching this thread. I plan to use my donors exhaust and I think I just need to shorten it. One cut and weld it up... wish me luck lol.

Are there any rules of thumb for exhaust clearance? Distance from cab, frame, rear axle, and the bottom of the wood bed? Should I get or use heat shields for the bed and under cab where the gas tank is?

as much room as these trucks have underneath the frame to the bottom of the body clearance is usually not an issue

[Matt_50]

My idea of shortening the donors exhaust didn't really work. It hangs below the frame a little. So I'll be watching what b-mac does.

Check out what I noticed. Not sure how I missed it but when the shop put in my motor I'm guessing exhaust manifold was already messed up orbthey messed it up.

[b-mac]

Originally Posted by _Ogre

as much room as these trucks have underneath the frame to the bottom of the body clearance is usually not an issue

I hadn't considered this. So you're saying go between the cab and the cross member, rather than under?!

It just might work!

[b-mac]

Originally Posted by Matt_50

My idea of shortening the donors exhaust didn't really work. It hangs below the frame a little. So I'll be watching what b-mac does.

Check out what I noticed. Not sure how I missed it but when the shop put in my motor I'm guessing exhaust manifold was already messed up orbthey messed it up.

Wish I had a lift so I could take better pics for you.

Not sure what engine you're running but maybe different manifolds or headers could get you closer to the block.

[Matt_50]

My donor has the exhaust go along the trans, in between the crossmember and the cab. The crossmember was shaped real gunky to do that though. I'm running a 350, I'll need to do some searches on here to see what I should look for a swap meets. I wish I had a lift too lol

[_Ogre]

Originally Posted by b-mac

I hadn't considered this. So you're saying go between the cab and the cross member, rather than under?!

It just might work!

most of truk exhaust hangs under the frame above the scrub line

[Matt_50]

Doesn't look like it does by much, maybe I can't see it very well. If I left mine the way it was hanging.. I'd be a good 4 or 5 inches below bottom of frame. Yours looks good, I'm just a tiny bit jealous lol.

[Volfandt]

$4oo.