5" to 7" Single

DIY 5" Turbo Back to 7" Single Miter

Original Writeup By 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

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0289.jpg

here is a shot of what I started with.

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0279.jpg

10Ft of 5" pipe.

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0283.jpg

12" of 5" flex

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0282.jpg

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

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0281.jpg

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

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0280.jpg

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..

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0295.jpg

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

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0286.jpg

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

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0284.jpg

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

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0285.jpg

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

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0276.jpg

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0277.jpg

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0278.jpg

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

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0288.jpg

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

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0297.jpg

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.

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0298.jpg

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...

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0290.jpg

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

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0293.jpg

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0291.jpg

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...

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0300.jpg

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

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0299.jpg

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

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0301.jpg

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...

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0304.jpg

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

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0305.jpg

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0306.jpg

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0309.jpg

Ok here are some pics

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0312.jpg

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0314.jpg

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0315.jpg

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0318.jpg

Now for the bad news...my t-bar clamp did not hold the stack tight and it slipped down and messed the paint up

http://i81.photobucket.com/albums/j240/53willys/Dodge%20Stuff/DSC_0319.jpg