Those of you who are regulars on CompetitionDiesel.com may have seen this stack install as part of a contest. The winner (Matt Wills of Middleburg, FL) got the stack kit at a huge discount, free installation at Garmon's Diesel Performance in McDonough, GA, and an install on their truck in this magazine.
The Silverline Universal Black Stainless Stack kit are nickel plated for a black appearance. It's a unique polished look that resists smudging and hides soot buildup on the finish.
The stack kit features 5-inch in-bed 409 stainless steel tubing with polished black stacks in either miter but or turn-out tips. The stack kit features a unique splitter plate that divides exhaust flow evenly between the two stacks to ensure proper sound and performance.
As for the shop behind the install, you might be wondering why Wills traveled to Georgia to have the stacks put in. Garmon's Diesel Performance is run by Jeff Garmon, who built a Silverline-backed Dodge Cummins drag truck that was built to compete in the Pro Street drag racing class. Garmon had a 2006 best time of 11.17 seconds at 127 mph in the quarter mile while running a single charger on fuel only.
Unpack product and lay out all of the components of the stack kit. Get the tools prepared for the install.
First, check the Y-pipe for fitment inside the bed. Measure to find the center of the bed from both inside the bed and below the bed. Account for the distance from side to side.
Determine where you want the stacks to come up out of the bed and take measurements. Make sure this measurement includes the clamps in the bed.
Check the fitment of the flex elbow beneath the bed.
Mark the bed floor for the Y-pipe to pass through.
Use a cutting disc to cut the hole in the bed. There will be a trim ring to cover the edges, but you need to follow the line closely. Use a reciprocating saw to cut the support frame away from the hole. Use a grinder to smoothen the edges of the hole.
Remove the existing exhaust system from beneath the bed. Measure the correct length of remaining exhaust pipe using the flex pipe and elbow to get the right measurement. Cut the pipe where needed and de-bur the edges of the pipe.
Install flex pipe and elbow with provided clamps, but don't tighten them yet.
Align cosmetic ring with the hole in the bed and mark the screw holes. Drill the holes. Slide the cosmetic ring onto the Y-pipe and install the Y-pipe into the hole in the bed. Don't tighten the clamps.
Double check the alignment of the Y-pipe in the bed by measuring the Y-pipe from both sides and the back of the bed. Line up and mark the left Y-pipe extender for the correct length.
If needed, cut Y-pipe extender to fit the desired placement. De-bur the edges of the pipe if you cut it.
Install the left Y-pipe extender into the Y-pipe and install the band clamps. Don't tighten them yet. Double-check your measurements here.
Install both stacks into the Y-pipe. The Y-pipe extender may need a little encouragement with a rubber mallet. Use a level to make sure the stack is perfectly upright (first making sure the truck is on level ground).
Measure for the desired height of the stacks and make any necessary adjustments and mark for the cut. Cut the stacks for desired height and de-bur the stack cut. Double-check your measurements and repeat the process for the other side.
Remove the stacks temporarily and place the stack rigidity clamp against the bed frame. Mark and drill the holes. Replace the stacks and install the mounting clamps. Don't tighten the clamps yet.
Check the stacks for correct alignment and begin tightening clamps. First tighten all clamps in the bed, then tighten all of the clamps beneath the bed. Re-check the stacks for any shifting and adjust if needed.
Make marks at all conjunctions to allow for expansion checks at a later date.
Check system using marks for movement periodically to ensure no shifting has occurred.
Movement during install is unavoidable. Be sure to check for movement throughout install steps to ensure desired outcome.