brianp454
Member
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- Location
- Portland, OR
WOW, lots of activity on mufflers. Without a muffler I found my truck would tickle my eardrums when at freeway speeds on grades, which is WAY too loud. I decided to install the AT3535XL because I wanted a little growl, but wanted it to be bearable without ear plugs. Also hoped to keep a little C turbo whistle. Got it for about $90 on eBay with shipping. Pics attached. I also put a video on youtube. If you search my screen name brianp454 or 3535XL you should find it. I installed the tip of the pipe at 111 1/2 inches from the ground (she’s wearing 365\80R20’s which are the same height as 11x20’s). The apex of my bows are at 113 inches, so I can always use the tip of the exhaust to confirm I have enough room to fit under something. My J-pipe had a mondo hunk of JB weld in a rust hole that was vibrating apart and leaking. I used a strip of the pipe when I put the muffler to repair it. I cut v-notches about every 1 ½ inch to allow it to bend and follow the path. The J-pipe should be replaced, but this will work for a while. My support bracket under the flex was also broken, so I used a piece of it and the leftover 3 ½ inch clamp welded together to make a new bracket. I think it’s better than the original. It looks like it was there from the factory and I notice NO increase in EGT's!
The disadvantage of the long AT is the hand guard will not fit. I plan to add a 1 ¼ inch welded-in extension to allow it to fit. Will post on it later. My truck has the Gillespie CARC sub 686 and I find it turns pink when it gets real hot. Hope the handguard will hide some of it.
I did take sound measurements with a professional meter beforehand, but have not had a chance to do it post-muffler. I will add to the thread when I can.
My buddy has the big (long version) Donaldson on his truck and it is quieter than the AT3535XL (see post 76 for my list of muffler options). If you are looking for quiet as possible I recommend the big Walker \ Donaldson. Also, I don’t think it is necessary to run the exhaust all the way to the back as some have suggested. If you really want quiet I would recommend mounting a larger muffler and dumping the exhaust pointed down about a foot from the intermediate axle. Trying to fit a muffler with the existing pipe size and straight design really limits muffler options. You can mount a wide variety of big mufflers under the truck and directing the tip towards the ground vs to the side should help too. So, if you cut the J-pipe about 2 inches under the support bracket (to allow it to hold it), run a bend to run the pipe straight down a foot or so, turn in until you’re roughly under the frame rail and then turn straight back. There’s plenty of room for a big muffler between the tank and the driveline. You can then add a custom tailpipe to direct the exhaust back and down at a 45 degree angle. I would suggest making the tip below and at least a foot in front of the axle so it doesn’t heat the axle. Also, you might consider a sheet metal heat shield between the tank and the muffler. Just leave room to allow air flow on both sides.
Added Muffler Parts:
AeroTurbine AT3535XL (long version with internal resonator) sandblasted to rough up surface for painting
Torctite stainless 3.5 inch strap clamp, 33223, 0113196 (2 required)
6 inch clamp, NAPA 733-5795
Mr Gasket 1203 or Fel-Pro 2003 (3.5 inch collector gasket with corners cut off)
Custom stainless bracket to adapt the 3.5 inch clamp bolt pattern to a 6 inch clamp
Primer and Desert Tan paint
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