3” Dual Exhaust Build w/ X Pipe

Moving slowly at this point. There’s a lot to think about to make sure I get through this one time without any mistakes.

The X-pipe was a bit of work to make, but the geometry and layout was simple. Now I have to make it fit to the truck.

I’m trying to bridge the gap between the ARH mids and the TRD tails. Since I’m limited on tooling and working in the ground trying to get perfect butt weld joints is going to be near impossible.

I had a thought to try to expand the joints, but this was a job for the pros. I did rent a mechanical expander, but it’s just not going to budge 304 stainless.

Shout out to Aces in Houston. They hydraulically expanded all the pieces I needed in about 5 minutes. that gives me so much more flexibility for adjustment during fit up.

So here is where I am now. I have the pieces mocked up on the floor. That and I’ve tacked the X-pipe in place with the stainless flanges to the midpipes. Hopeful that I’ll be finished this weekend but we will see.

 

More progress. Got everything fit and tack welded in place. The TRD exhaust had some type of pressed V band flanges that had to go. So I cut those off the tail pipes and welded bigger 2 bolt flanges. Even got some stainless hangers back in the mix. Here she is compared to the old TRD. Just need to seal weld all the joints and install it now.

 

All done. Stayed up late last night welding everything. Installed this morning. I think it sounds perfect. Barely louder that the TRD when cruising. No drone. But man is it rowdy when on the gas. Definitely feels like it is flowing better and feel like the truck is moving quicker. Fun project. Check out the YouTube

 

Epic vid! Very Nice! Lol

 

Sounds really nice in the vid

 

Those kooks mufflers sound pretty damn good. Video was a good wrap up on this task well done.
Didn't realize your a local Texan either. Spinning at 50mph...

 

Pretty dang snarly!

 

After a few weeks driving, i still love it, but have noticed one spot where it drones. in 6th gear right at 60 mph at approximately 1600 RPM there is a drone that is present, but goes away pretty quick if i go just over or under 60 and get out of the 1600 RPM range. I downloaded a few apps that are telling me the frequency is around 140 Hz when it happens. Its so minor that i am not even sure i want to mess with it. On the other hand, i love messing with this kind of stuff.

I've played around with some physics calcs for 1/4 wave and for Helmholtz and have a couple potential solutions. Alternatively i could weld in some inline resonators and see. Inline resonators seem a little more uncertain since none of the manufacturers really give any specs to what frequency they are tuned to. Just seems like a copy/paste from manufacturer to manufacturer. The 1/4 wave and Helmholtz style seem a lot more scientific and allows me to dial in on the problem area. I just hope in doing so it doesn't move the drone to another frequency. Not even sure if that's possible.

 

You may be able to pick Dirty Deed's brain on this, it's something he seems to mention relatively often in reference to his systems. I have his single-exit 10 inch replacement on my RCSB. Without his resonator, the drone under the conditions you're describing were eyeball liquifyingly bad for me. His resonator sorted it in my case. I understand that our systems are different, but it could still be worth the effort asking...

 

Damn mine is nowhere near that bad, more like a "huh, that seems louder" type thing. The first system i ever put on this truck back in 2007 was a Volant 3" that droned at all highway speeds and was unbearable. Hard to believe some exhaust manufacturers even put systems like this out when the technology/principles of resonance management have existed long before the automobile.

 

Believe it or not, that's a characteristic that some people are looking for. I was surprised at the initial test drive as well, but as mentioned the resonator took care of it. Something that people probably seldom take into consideration is the organic aspect, like ear shape, head and sinus cavities that could all resonate at particular frequencies making it "awesome" for one person, "painfull" for another. Not unlike what's experienced with the sense of taste.

 

@swank501 man, serious respect in your window build and this.. I like your style. It's nice to see custom stuff other than the typical bowing down to the same thing every time a topic gets brought up

I'm assuming your mids are 2.5"? What flanges did you source connecting those to the 3" piping for the x-pipe?

 

Thank you. It was a fun project for sure. My ARH mids are actually 3", but neck down to 2.5" at the muffler flange. I found some 304SS 2.5-3" adapter flanges on ebay for this job that worked perfect.
I was a little trigger shy to cut up the ARH mids to put proper 3" flanges in case i needed to revert. Now that ive been driving for the last few weeks, i really like it and plan to keep it. I think the next move will be to cut off the 2.5" flanges and go with 3" flanges, and add 1/4 wave resonators to target the minor drone im getting at 60mph.

 

Link to ebay flanges?

 

https://www.ebay.com/itm/132032652949

These are what I used, but the price is now 10x what I paid for mine for some reason. I suspect they are out of stock right now hence the pricing.

 

LOL, a person can now finance their exhaust flange purchase...

I just read in the description that they're being sold at below cost.

 

They really are. I pad $13/each for mine. These are drop cuts when they modify their downpipes for different applications that they then resell. I don’t think you can buy a flange alone for that.

 

Thanks. That's ridiculous, better be made out of an adamantium alloy.

 

Nice display of skills.

I assume 3” duals is pretty much FI only?

 

What is FI? For the 3” duals you need to be putting some power down. I’m close to 600whp

 

I was joking. "At a loss" at the +$100ea price.

Forced Induction...

 

Yep. Forced Induction.

Doubt I’d ever go that crazy with my Tundra, good to know I can stick with my Borlas. I went nuts with my Lexus, the more stuff I added on the less fun it was to drive. But that could be due to the fact that our roads are so terrible I could never do anything.

 

Any updates on this? Did you ever build out the 3" flanges, or Helmholtz resonators?

 

I did not. Maybe one day I will, but I feel like I may be chasing something I don’t really need to. It sounds good and makes a ton of power. Any changes made now could potentially change something I like as well.