Well I jumped in both feet on this one...

Once you pull out a sawzall you're kinda committed (I think my wife wants to have me committed now)

It's not that there was anything wrong with the stock exhaust - but this looks so COOL!

First parts out - you can see the MagnaFlow 5" tip I had on the modified stock exhaust:

Old parts waiting for their next destination...
Everyone I spoke with said the down pipe would be tough - maybe because I was generous with the penetrating oil and patient to let it work I didn't have a problem.

Getting everything back together was a bit easier than taking it apart surprisingly:

But there is a problem:

In this last photo you can see how the tail pipe is contacting my rear fuel tank armor. It seems like the pipe is a bit short as the hump over my rear axle is not centered...I'm pretty sure this kit is for the long wheel base crew cab F-series but it still isn't quite right.

I'm going to spend a little more time under the truck this evening when it's not so hot...any ideas from other aftermarket exhaust installs? Thanks for looking and any advice!

Jonathan D. Howell
Major, U.S. Army

2005 Ford F-550 with 6.0L PowerStroke Diesel
EarthRoamer XV-LT #15 "Around the World"
"Americans Travelling America"

Coolant Bypass Filter, Oil Bypass Filter
Bigger Intercooler with bigger boost tubes

Next: Transmission bypass filter

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Well, I pulled the tail pipe off for the moment. The exhaust is not quite right. I'm gonna call the mfr tomorrow and see if I can get some help - or perhaps a different tail pipe section as it seems that the whole install is a bit off.

It sounds like a low growling rumble with lots of turbo whistle - especially at start up.

Jonathan

P.S. Anyone have access to a mandrel bender in the Jackson-Vicksburg area?

 

So I'm still looking for somewhere I can bend 4 inch pipe without creasing or splitting. I am also still working with the mfr for options. Ideally I want a straight shot out the back rather than the turn to the right behind the passenger side rear wheel. I might have to cut the secondary intermediate pipe (it's about 24 inches long) and move the muffler forward a bit to fit a 90 degree elbow and exhaust forward of the passenger side rear wheel. That's better than what I have for the moment - straight back exhaust from the rear of the muffler onto the rear axle.

Jonathan

 

Any word from Banks with that exhaust? I would think any competent muffler shop could fab something up? Maybe a speed shop in your area or a big truck shop?

 

We are exchanging ideas at the moment. Of course I would prefer that it had worked flawlessly but I am satisfied with the attention I'm getting to address the issue. Seems that the fuel tank versus a spare tire in the space behind the rear axle is what is causing the difference for my situation. I'm hopeful I'll be able to return the current tailpipe and get a slightly modified tailpipe that will clear the rear axle and fuel tank with sufficient tolerance and then run straight back to the rear rather than behind the rear passenger tire - the reason is that the cabin on the frame rails has windows that could draw in exhaust although there are EarthRoamer models that have the exhaust on the side, those systems are still much further to the rear of the truck than behind the rear wheel. Thanks for the continued interest - a truck shop, machine shop may eventually be an area I look at for support but Banks is working hard to solve my challenges.

Jonathan

 

I'm glad Banks is doing something, that is one good thing they have for them is their customer service from what I've seen as long as you're not on CompD

Also maybe check out Jegs or Summit Racing. I remember in Jegs, they had 4" and 5" universal diesel exhaust systems for like $200 or so, and you could probably buy a kit and piece together some sections and make it work maybe?

 

I should've done this some time ago...I checked the manuals on the Banks website today because I forgot my manual at home and I haven't gotten a call back from tech support.

So I discover that I was sent the WRONG KIT.

I got a 250/350 kit instead of the 450/550 kit. That is what I suspected as regarding the (lack of) fit for the tailpipe. The 250/350 had a spare tire behind the rear axle standard while the 450/550 have a fuel tank standard behind the rear axle. That make a difference on the angles for clearance. There were two other parts that were different but the primary difference is the tailpipe.

Banks is sending the (assumed) correct tailpipe for the 450/550. I'm supposed to get a return label for the 250/350 tailpipe I have. I'll get a credit for shipping too - so ultimately an even swap.

Of course there is still a complication...

I'm headed to Korea for one month to support annual military response training. The completion of the install will be delayed.

I'll report later the success (hopefully)

Jonathan

 

Sounds good, thanks for keeping us posted.

 

Back from Korea finally. The tailpipe for the 450/550 arrived but I still need an RMA to get credit for the 250/350 tailpipe when I return that to Banks. I'll be attempting to complete this installation this weekend!

Jonathan

 

Good luck with the install(it should be easy as pie)

 

I didn't wait...
The new tailpipe went on perfect last night. Very nice to see the proper fit. I'll get a new photo of the (finally) complete install.

Jonathan