'89 R3500 Crew Cab 2wd to 4wd conversion & beyond

[mrk5]

Yeah. I tell myself it's why I don't own/work in a muffler shop. Not that I've seen the best work come out of a few if the muffler shops either.

 

[mrk5]

Well, I was hoping to finish the exhaust today but it kicked my ass. I didn't plan for the hangers and my attempt to improvise didn't work. So hopefully I can finish next weekend.

I did at least get the O2 sensor installed so I can fire the motor once everything is ready even if the exhaust isn't finished.

That's not the new sensor. I threaded an old one in during welding.

The front part bolt in well. I thought it would be the hardest part but it was not.

Started on the rest of the system with a v-band flange at the end of the y-pipe.

Have placement of the muffler figured out. It fits, just. It works best at a bit of an angle.

In the next picture on the right side you can see my crazy attempt to make an existing hanger work. It didn't work....

I have a plan but needed to order some more stuff. If I would have had even a simple clamp I might have figured something out. Since I'm trying to use the v-band clamps I didn't buy any traditional exhaust clamps.

 

[frankin5]

Is it an optical allusion or are your spring eyes resting on the frame?

 

[GWeakland620]

Is it an optical allusion or are your spring eyes resting on the frame?

They do look crazy close if not.

 

[skunked]

I had to angle my muffler in that same spot.

 

[mrk5]

Is it an optical allusion or are your spring eyes resting on the frame?

They are crazy close. I made 1/2" longer shackles after my initial install because they would contact. Now they just barely clear. It's funny you mention it because I look at that EVERY time I crawl under the truck to see if they are still clear.

 

[AgDieseler]

Custom exhaust can be a lot of fun. Looking really good.

David

 

[mrk5]

Only thing not fun was not getting it done like I'd planned. In the end I will have a system much better than I did with easy to remove sections which will make things like removing saddle tanks easier. That's something I'm excited about. Also very curious how it's going to sound.

 

[GWeakland620]

I bet it'll sound just like a big block.

 

[mrk5]

Which is new for me. Only big block I've had experience with was the 383 in my 71 cuda.

 

[Truckman4life]

I had a v10 dodge for work that I put a 50 series 2 into 1 muffler on and then kicked it out the side before the rear tire. Sounded good for a v10, flowmaster even told me that a v10 won't ever sound good lol. I think they are quiet enough but still throaty when you get on it. Me personally, I like something a little louder all the time. Especially on a long truck when the tail pipe is way back from the driver.

 

[ktmoutfront]

We are 1/2 way through "next weekend". Where is the video of it running?

 

[mrk5]

Unfortunately no. I guess I'm taking too much time trying to get things just so.

Ran into a bit of an obstacle with the power steering pump to hydroboost pressure line. Tried the line made for the pickup '89 R3500 but I couldn't get it to line up well. So then I tried one for an 84 K5 with 6.2 but then still had a problem. It's the shock hoop that's a problem. I had to bend the line to fit.

Which puts the rubber portion in kind of an S bend. May have so make some lines using AN fittings.

The reason for the trouble is the 454 is longer. You can see here in the hose from the reservoir. With the 350 it was straight over but with the 454 it is angling forward.

The Holley Sniper doesn't come with a PCV port like a carb typically does. There is a 3/8" port on the back but I decided to get all fancy with some leftover AN fittings I had on-hand. Used a port on the intake manifold.

The 3/8" port on the Sniper would work as well.

You can also see the fuel lines are hooked up. I used a black hose end for the return and the shiny for the feed. Best option I could find for an inline fuel pressure gauge is FiTech's.

Ran the fuel pump and all seems good after tightening the clamps on the tank selector valve. Pressure held at about 60psi.

Wired up the starter solenoid. Dropped the wires to the starter down the back of the motor.

Did manage to get the exhaust finished up. You can see why I call it Frankenstein exhaust what with all the seams.

There are 2 v-band clamps in the section between the y-pipe and the other near the muffler.

Used up an entire U-bend for the 3.5" section of pipe. Figured I'd keep with the Frankenstein theme and welded every last piece to the end of the tailpipe.

What's left? Need to wire up the Sniper and the gauge sending units.

 

[ktmoutfront]

Progress is being made. Cool.

 

[Truckman4life]

Where's the 8" tip? You should have painted that yeller firewall when you had the engine out. What's left to fire this thing?

 

[mrk5]

Where's the 8" tip? You should have painted that yeller firewall when you had the engine out. What's left to fire this thing?

3.5" is big enough for me.

Gotta wire up the Sniper which will talk a little time because I need to try and be as neat as possible with wire routing. Some of it is going to be a pain because the provide extra length that can't really be trimmed out. So far the Oxygen Sensor wiring is going that way. Probably have almost 2ft of wire to do something with. The way it's wired up I can't cut and splice easily. I think most of the wiring I'll be able to deal with easily enough.

Then I need to fill the coolant. Wire the gauge sending units. Wire the fans.

So mostly wiring. I actually enjoy doing it but it can be time consuming. I take 1hr breaks twice a day to go work on it. I think there's a good chance I can fire it before the weekend. Depends on how work goes.

I also need to bleed the power steering system which can be a bit difficult with hydroboost and the steering ram. I'm going to pull the belt and do the initial startup without the steering pump. Mess with bleeding that once the motor is running.

 

[mrk5]

Maybe I should add an 8" clamp-on tip for cruising around town.

 

[Bent77]

Maybe I should add an 8" clamp-on tip for cruising around town.

So many jokes there

 

[mrk5]

So many jokes there

Yeah, I struggled with trying to word that as cleanly as possible but decided it was a hopeless cause.

 

[skunked]

Did you get the fuel pump/tank reinstalled?