This past weekend my son helped me do some modifications to the truck. I want to thank the super techs and very educated drivers for all their input on this forum.
The tech folder is great.
1. Up-Pipe. We had a real heck of time getting it off. FINALLY the correct method is to remove the upper and lower manifold bolts before trying to take the clamp ring off the EGR connections. Have to back off the thread on the clamp all the way. We noted there is a large scoop inside the pipe that routes the exhaust into the side port on the pipe to the EGR cooler inlet. We were going to drill/grind that out but forgot. It blocks about 1/2 the flow. I really messed up there. We found a washer that we ground down to fit inside the flange and welded it shut. Installation was not real easy but with me on top of the engine and him under the truck we got it back.
I wish now I would have spent the money to buy the after-market up pipe and plug cap. But the low cost option does work

2. Drop the exhaust. Cut off the muffler and opened the pipe turbo back. We used the 3.5 in pipe- I could not afford the 4 inch kit at this time. We bought a section of 3.5 in pipe and band clamps also a 2 ft section of flex pipe. We figured without a bent pipe we were going to have a real problem getting the pipe to weld up due to the angles. It went together very nice. I think the flex pipe will hold up for a long time. Later I can get the 4 inch cat back. The cat is installed for looks...

3. The EGR valve is disconnected. If I left it connected it would not run smooth. Here is my technical reason why. The EGRV opens when there is no intake boost- foot off the throttle, or just light pedal. The NORMAL operation assumes there is exhaust gas pressure in the cooler and at the valve. The valve opens lets high pressure gas flow into the intake and engine. When you ask for power, the valve has to close to keep pressurized intake air in the intake and not back to the cooler. With the above block in place there is no pressure in the cooler section. When the valve opens, it fills the chamber with intake air, flow the wrong way. The PCM does not get the correct feed back and appears to be cycling the valve open-close. Plus no way to know what happens to air flow as it is ported to the cooler chamber and the intake. I fixed this by disconnect. Runs great.

Now with the codes set and the CEL on, I have the call into Eric for a SCT. Thus the reason for the 3.5 in cheap open pipe and the DIY uppipe weld. The $400 is to put out the CEL and of course get a bit better mileage. I really do not need any more power- just a good safe street tune with no load and a safe tow tune, no real boost in power. Still have stock head bolts.

4. CCV re-routs. This was the easy fix, other then taking the intake system apart. We plugged the hole in the intake tube with a 1 inch rubber freeze plug with lock tight and two nuts. I used clear tubing, 1 in ID to route the vent under the truck. I used 1 1/4 sump pump hose to route it behind the axle. I guess it works I did not smell any fumes but there was some oil film in the clear tube.

Road test.. A great improvement. Sound is wild. Sounds like a fan jet. Turbo spools up fast no lag. With a stick I really need that lag time off the line to improve. With EGR operation there is a real lag before the valve closes and boost starts to build. Plus when I shift there is the lag back or suck back when I let the clutch out and feed the fuel due to the EGR operation. Its all gone now.
I was pulling a flat trailer and farm tractor at about 6000 pnd for a combined weight of 13k or so?
The response was significant. The throttle sensitivity was noticeable. It would wind up the RPM so much faster, I was shifting quicker. POST EGT ran normal about 550-600 on the flat at 2000 rpm 4th gear. Now runs 400. Water temp -real gauge- 200 plus now 190. Pulled an 8 to 10% grade in 3rd/4th RPM at 1900 to 2400. EGT never hit 600 hung around 500 to 550. Water temp never hit 212 which it did all the time. Cool down improved, faster when I got off the power. Boost never over 25psi.
These basic mods while time consuming and not all that easy have made this truck really so much better. I am sure when I get the SCT programs loaded it will be great.
I will get pictures posted to my pix site and post the URL later.
I had a few more comments but this is long enough .
Thanks

 

Pictures here

 

sounds like you had some fun. Thanks for the picture and the write up it was nice reading.

Thanks