Power Slug Maintenance - Exhaust

From the begining I wanted to get better flow of exhaust by adapting 2.5” pipe and a better muffler. The group consensus is that wider pipe means better flow, resulting in reduced EG temps. Just another tweak to getting the little diesel engine to stay cool so a few more RPM can be squeezed out of her. She’s been doing just fine between 65-70 MPH on the freeway under normal ambient temperatures, but with extreme heat and humidity (90+) she still gets warmer than I would like, so we have to slow it down a touch. Hopefully the exhaust upgrade will help out.

The original exhaust now had TWO holes and was sounding pretty bad, so it was time to tackel this one. Found some pre-fitted 2.5” pieces from the Great White North and just need to put them together with a new Magnaflo muffler…

… pay someone to do it, or learn a new skill? Aaaaaaand now I’m the proud owner of a new welder! With some practice, I should be able to handle this.

Let’s see how I did…

The goal here was to get the 2.5” downpipe welded on as close to the flange mounting to the turbo since I can’t fabricate my own 2.5” flange. That would be ideal. Then I needed to extend the 2.5” downpipe to the 45 degree bend into the new muffler. Lots of bits and pieces used here. Finally, the angled 2.5” side discharge that I got from the chap up north needs to go onto the muffler exit flange.
This is what I started with: