Hi all,

I don't post here much, but it's a useful resource when working on my truck. I have a 96 half ton with a 5.8 that needs a whole new exhaust system, front to rear. Just poking around here I've picked up a few things, but I have some questions before I start spending money.

I'd like to spend this money once and do it right, so I'm looking at all stainless everything, ceramic coated headers, etc. I'm hoping to see an increase in torque and maybe even a slight bump in gas mileage (probably not realistic, but I can dream) As far as sound goes, I'd like a nice deep rumble on acceleration, but I don't feel any need to wake up the neighbors and I definitely want to be able to have a conversation while driving down the road. Right now I'm looking at this:
https://www.summitracing.com/parts/j...rd/model/f-150

This:
https://www.summitracing.com/parts/m...rd/model/f-150

And this:
https://www.summitracing.com/parts/g...rd/model/f-150

So my questions are:
1. Is this the best way to go? Or are there other parts that would get me to my goals better? Summit is usually just the first or second place I look for parts and some of you might know of something better.

2. At some point in the future, this truck will need an engine rebuild (or a rebuilt engine...or a built engine...). I'm not ruling out aftermarket heads, but most likely I will go with a set of junk yard GT40s or GT40Ps. Is it reasonable to assume these headers will work with the heads I put in my truck down the road?

3. Right now the exhaust has some perforated heat shielding between the cat and the muffler. Given that I live in tallgrass prairie and I do sometimes pull my truck out into a pasture. That means I need to be concerned about the hot exhaust starting a grass fire. It happens occasionally around here. It tends to make the landowner upset with you, not to mention the local volunteer fire department. It also tends to result in the total loss of the truck. Is there heat shielding like that available commercially? I've thought some on how to fab up something, but if it's available for a reasonable cost I would probably go that route.

4. Does anybody know where I can find an EGR tube for a 96? The ones I see for sale on Rockauto, etc. don't look like they have the two little sample tubes that mine has. I need to replace my EGR valve also and from the looks of it I am not confident the EGR tube is going to come off and go back on in one piece.

Thanks in advance,
Greg

 

1. Depends on your definition of best. You have selected parts that are a simple bolt-on that will improve performance but mostly at midrange rpms. If you want the most low rpm torque gains then you need longtubes, the only problem with those is there are no ready made intermediate pipes available so you have to DIY something or have an exhaust shop fab it.

2. The P heads require specific headers but everything else including aftermarket heads can use any standard header.

3. Can't help with heat shielding.

4. Try searching for a DPFE tube, you are correct the chances of the tube coming off intact are low.

 

Can't help you with the EGR, but I have the SS uncoated version of those headers & they've been great.

Had them on & off 3 times & they went back on each with fel-pro gaskets & I've had no leaks.

Wasn't real impressed with the original supplied gaskets, but they worked fine. (looked like gasket was covered in fuzzy black plastic)

I have My Bassani Y & the headers themselves wrapped with DEI Titanium wrap.

It doesn't require a "treatment spray" like some brands do & it does cut down on heat heat under hood & immediately down stream.

I pieced the rest of my system with a Magnaflow cat, SS 3 chamber muffler, 3inch pipe & a Dynomax tail pipe, SS, mandrel bent tail pipe for a late model Ford Diesel.

 

Conanski,

That's what I figured about long tubes and a mid pipe. That's why I was looking at shorties. I don't do a lot of heavy towing or off roading with this truck anyway. It's mostly a daily driver/haul stuff around in truck for me. So it's not the worst thing in the world if I don't see a big gain in low end torque. I'm also trying to keep the total budget for this project at or below $1500, so custom fab is pretty much out of the question.

And thanks for the tip on looking for a DPFE tube. I found what looks like the right part though it's listed as being for a 95, but wow is it expensive. I guess that's a bullet I'll have to bite though.

Greg

 

Scndsin,

Thanks, it's good to hear about some experience with the header I'm looking at. That Bassani Y pipe is going to bust my budget though. So I'll likely go with the Magnaflow unit. And I hadn't thought about using header wrap as a heat shield. That's something to look into.

Greg

 

Nothing wrong with that.

I love the wrap, save it will make you itch if you rub on it with bare arms.

We can talk about pasture fires.

Good quality band clamps are worth it.



I used to run just the turn down but after my rebuild I had to quiet it down.

Found this looking through Summit on line for under $100.

Drilled one hole & used one of the hangers.



I built my system 1 piece at a time. Started by off cutting the nuts off the stock manifold with a dremal disc & putting on the Y for a while before getting the headers.

 

Scndsin,

That looks good. How long have you had the wrap on there and how is it holding up? I've never messed with header wrap before so I don't know what to expect.

Also, one more question. I'm not a welder. Is it a good idea to weld the joints in the system (not the bolted joints, of course) or will clamps work fine?

Greg

 

I've had the Y wrapped for about 3 years & the headers 2.

Little fray at the cuts, but if you wrap continuously, it seems to be not an issue.

I've got no welds at all, it's all clamps, mostly band style & a couple stepped band style.