So I decided to move up to 4” exhaust, and being the cheapo that I am, I cobbled together my own kit. I thought I would share what I did, and how it turned out.
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The plan
My truck is a ’94 IDI factory turbo, with the ATS 3” turbo housing and 3” down pipe with ATS 3" exhaust after that. My plan was to use a 3” to 4” adapter after the down pipe. Beyond the adapter I would run two sections of 4” straight pipe, then a MagnaFlow 4” tail pipe for a ‘95+ Powerstroke truck. Holding all of this together would be band clamps.
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The truck only has 3 exhaust hangers. One by the transfer case, one in front of the rear axel, and one behind the rear axle. All of these would be address by guillotine clamps. The transfer case and rear of axle hangers needed to be cut off the current 3” clamp mount and welded to a 4” clamp. The mid hanger was a bolt on affair.
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The parts list looks like this:

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<table class="MsoNormalTable" style="width: 426pt; margin-left: 4.75pt; border-collapse: collapse;" border="0" cellpadding="0" cellspacing="0" width="568"> <tbody><tr style="height: 12.75pt;"> <td style="border: 1pt solid windowtext; padding: 0in 5.4pt; width: 1.5in; height: 12.75pt;" valign="bottom" width="144" nowrap="nowrap"> Item<o></o>
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</td> <td style="border-style: solid solid solid none; border-color: windowtext windowtext windowtext -moz-use-text-color; border-width: 1pt 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" valign="bottom" width="64" nowrap="nowrap"> Quantity<o></o>
</td> <td style="border-style: solid solid solid none; border-color: windowtext windowtext windowtext -moz-use-text-color; border-width: 1pt 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" valign="bottom" width="64" nowrap="nowrap"> Ext<o></o>
</td> </tr> <tr style="height: 12.75pt;"> <td style="border-style: none solid solid; border-color: -moz-use-text-color windowtext windowtext; border-width: medium 1pt 1pt; padding: 0in 5.4pt; width: 1.5in; height: 12.75pt;" valign="bottom" width="144" nowrap="nowrap"> 4" x 4' tubing<o></o>
</td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 80pt; height: 12.75pt;" valign="bottom" width="107" nowrap="nowrap"> SUM-640040<o></o> </td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 94pt; height: 12.75pt;" valign="bottom" width="125" nowrap="nowrap"> <st1:city w:st="on"><st1>Summit</st1></st1:city><o></o>
</td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" x:num="" valign="bottom" width="64" nowrap="nowrap"> </td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" x:num="" valign="bottom" width="64" nowrap="nowrap"> </td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" x:num="" x:fmla="=D2*E2" valign="bottom" width="64" nowrap="nowrap"> </td> </tr> <tr style="height: 12.75pt;"> <td style="border-style: none solid solid; border-color: -moz-use-text-color windowtext windowtext; border-width: medium 1pt 1pt; padding: 0in 5.4pt; width: 1.5in; height: 12.75pt;" valign="bottom" width="144" nowrap="nowrap"> Magnaflow tailpipe<o></o>
</td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 80pt; height: 12.75pt;" x:num="" valign="bottom" width="107" nowrap="nowrap"> 15457<o></o>
</td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 94pt; height: 12.75pt;" valign="bottom" width="125" nowrap="nowrap"> USDieselParts.Com<o></o> </td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" x:num="" valign="bottom" width="64" nowrap="nowrap"> </td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" x:num="" valign="bottom" width="64" nowrap="nowrap"> </td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" x:num="" x:fmla="=D3*E3" valign="bottom" width="64" nowrap="nowrap"> </td> </tr> <tr style="height: 12.75pt;"> <td style="border-style: none solid solid; border-color: -moz-use-text-color windowtext windowtext; border-width: medium 1pt 1pt; padding: 0in 5.4pt; width: 1.5in; height: 12.75pt;" valign="bottom" width="144" nowrap="nowrap"> 4" band clamp<o></o>
</td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 80pt; height: 12.75pt;" valign="bottom" width="107" nowrap="nowrap"> BK 733-5976<o></o> </td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 94pt; height: 12.75pt;" valign="bottom" width="125" nowrap="nowrap"> <st1:city w:st="on"><st1>NAPA</st1></st1:city><o></o>
</td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" x:num="" valign="bottom" width="64" nowrap="nowrap"> </td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" x:num="" valign="bottom" width="64" nowrap="nowrap"> </td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" x:num="" x:fmla="=D4*E4" valign="bottom" width="64" nowrap="nowrap"> </td> </tr> <tr style="height: 12.75pt;"> <td style="border-style: none solid solid; border-color: -moz-use-text-color windowtext windowtext; border-width: medium 1pt 1pt; padding: 0in 5.4pt; width: 1.5in; height: 12.75pt;" valign="bottom" width="144" nowrap="nowrap"> 4 exhaust clamp<o></o>
</td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 80pt; height: 12.75pt;" valign="bottom" width="107" nowrap="nowrap"> BK 733-5752<o></o>
</td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 94pt; height: 12.75pt;" valign="bottom" width="125" nowrap="nowrap"> <st1:city w:st="on"><st1>NAPA</st1></st1:city><o></o> </td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" x:num="" valign="bottom" width="64" nowrap="nowrap"> </td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" x:num="" valign="bottom" width="64" nowrap="nowrap"> </td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" x:num="" x:fmla="=D5*E5" valign="bottom" width="64" nowrap="nowrap"> </td> </tr> <tr style="height: 12.75pt;"> <td style="border-style: none solid solid; border-color: -moz-use-text-color windowtext windowtext; border-width: medium 1pt 1pt; padding: 0in 5.4pt; width: 1.5in; height: 12.75pt;" valign="bottom" width="144" nowrap="nowrap"> <st1:city w:st="on"><st1>Walker</st1></st1:city> 4" to 3" reducer<o></o> </td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 80pt; height: 12.75pt;" valign="bottom" width="107" nowrap="nowrap"> EXH-41890<o></o>
</td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 94pt; height: 12.75pt;" valign="bottom" width="125" nowrap="nowrap"> <st1:city w:st="on"><st1>NAPA</st1></st1:city><o></o> </td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" x:num="" valign="bottom" width="64" nowrap="nowrap"> </td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" x:num="" valign="bottom" width="64" nowrap="nowrap"> </td> <td style="border-style: none solid solid none; border-color: -moz-use-text-color windowtext windowtext -moz-use-text-color; border-width: medium 1pt 1pt medium; padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" x:num="" x:fmla="=D6*E6" valign="bottom" width="64" nowrap="nowrap"> </td> </tr> <tr style="height: 12.75pt;"> <td style="padding: 0in 5.4pt; width: 1.5in; height: 12.75pt;" valign="bottom" width="144" nowrap="nowrap"> <o></o>
</td> <td style="padding: 0in 5.4pt; width: 80pt; height: 12.75pt;" valign="bottom" width="107" nowrap="nowrap">
</td> <td style="padding: 0in 5.4pt; width: 94pt; height: 12.75pt;" valign="bottom" width="125" nowrap="nowrap"> <o></o>
</td> <td style="padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" valign="bottom" width="64" nowrap="nowrap">
</td> <td style="padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" valign="bottom" width="64" nowrap="nowrap"> </td> <td style="padding: 0in 5.4pt; width: 48pt; height: 12.75pt;" x:num="" x:fmla="=SUM(F2:F6)" valign="bottom" width="64" nowrap="nowrap"> </td> </tr> </tbody></table> <o></o>Shipping and tax is not included in the above numbers, but USDieselParts.com was/is currently running a free shipping special on the tail pipe. <st1:city w:st="on"><st1>Summit</st1></st1:city> is pretty expensive on the shipping for the tubing with the 12 handling plus the $7.50 oversize charge, but I didn’t want have to call around looking for tubing.
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The Install
It all went together pretty straight forward. Moving the front and rear hangers that needed to be welded took the most time as I’m a new to welding and 16gauge steel of the new hangers is near the limit of what my 110 volt welder can handle. All the hangers were raw steel, so I threw some high-temp black paint on them after all the welding was done. I love how fast paint dries on hot parts.
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Basically my process was to work from both ends and cut the middle section of pipe to fit what was needed. I mounted the adapter to the first 4” pipe, and then mounted that to the down pipe. I then mounted the tail pipe over the axle and got that to where I wanted it. This left a section of about 34” or so that would need to be filled with the second 4” pipe cut down from 48” length. Once the missing section was cut down and installed, all the band clamps were torqued to 50 ft-lbs. and the hangers were tightened to about 20 ft-lbs.
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All in, I think it took me 3 hours to complete the install.
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The Result
All I was expecting to get out of this was a new, not rusty exhaust that might be louder. I didn’t really expect any performance changes. How restrictive could 3” exhaust be?
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The truck is louder, but not really in the cab. When I get on it, it is louder, but again, not really in the cab. I often drive with the passenger window half way down to hear the turbo wine (I LOVE that sound), and I can hear more turbo spool, and I can tell others outside my cab would say it is louder, but I don’t think it is obnoxious or offensive.
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The part that I was not expecting is how much faster the turbo responds. From what I can tell so far, turbo lag is reduced by about half, and I’m boosting much higher than I was before. With the 3” exhaust I would need a big hill, or a big load to boost past 10 psi, but a full throttle stoplight start to 40 mph will now boost to about 14 psi. My wastegate is set to limit boost 15 psi max, and I expect the wastegate will be working more with this new 4” exhaust.
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Hope this helps you guys.

PS - if anyone near Seattle wants the old ATS 3" aluminized steel tubing, including a straight through 3" muffler, PM me. I hate to throw this away.

 

glad to here that, the less restriction you have in your exaust the better it will run, great to here you up your performance and didnt break the bank

 

Axe, I have a 94 F-250 sc longbed 7.3 factory turbo IDI. It only have the 2 1/2" downpipe. Where did you get the ats housing and 3" downpipe? I've been searching everywhere. Any help would be appreciated. Thanx, Marino

 

you can get it from ats

 

If you have the factory ford 2.5" downpipe, you will need the ATS 3" turbo outlet and the 3" downpipe. Last time I checked it was about $300 for both from ATS. You will probably have to call them because the new website is not linking to the IDI stuff very well.

 

Get on the Dynomax website and they have all the parts to install a 4-inch system on a IDI truck. I have it on mine now. I had to adapt it to the Banks system,basically using a 3-4 inch adapter to transition from the 3-inch Banks downpipe to the 4-inch system. You can buy an entire kit, including a front Y-pipe for an NA truck, or the bits and pieces. It's a bit too loud for my taste but I also picked up a little more boost. Picked up a little acceleration too. I did a story for Diesel World on it, but it hasn't appeared yet.

 

i just got the 3inch down pipe frm banks ...now im waiting on purchasing a whole exhuast kit frm a 94.5-97 i seen some on ebay from diamon eye for $270 delivered ...

 

I talked to an ats dealer today, he said he called ats and they are out of turbine housings, and not sure if they're gonna produce any more. I guess I'm SOL. Thanks for the info anyway.

 

You don't "need" the turbine housing. It's just easier to use than taking apart the old stuff.

BTW do you have any pics of the 4" magnaflow tailpipe? I used the Dynomax one which is about half the price, but I hate where it exits in the back of the truck.

 

Tail pipe ****:














Picture of 3" - 4" reducer installed on ATS down pipe:

 

Ah, that exits pretty similar to the Dynomax tailpipe. It's too close to the tire for my liking.

 

It would be pretty easy to change that with 2 4" band clamps and some 4" tubing. I would do that if it was worth the $25 the band clamps would cost.

 

Hey ghunt I called also and ATS said they are out. You said that I wouldnt need the housing - What else do I do?

 

Hum, maybe if ATS gets a call from a bunch of us they will make some more...

 

I would love to hear a video clip of the exhuast... just out of curiosity...