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I'll start pricing material and then let everyone decide what stainless we want.

I used these exhaust donuts on my original exhaust system without issues. Maybe plowboy can post up some measurements of the ones he found so we can compare? https://www.napaonline.com/en/p/FPB60986 It does seem there were quite a few differences in these trucks from early to late. I recently...

What kind of stainless did you use or find worked best?

The clamps in the link you posted look like the originals on my truck.

Would air tool oil work in there instead of the expensive oil? Has rust inhibitors etc.

I was wrong about the aluminum housing being replaced. It is the front of the housing that is replaced. Here is a better view of the housing and the replacement part. This is an airpak I rebuilt with the 5 ton kit. It's the one on my truck right now. I found and used an original M809 series...

I can use other metals. I just want to use whatever everyone is most comfortable with since this is an unknown for all of us. Also would like to be able to reuse the piston assembly.

Speaking with the engineers at work today, they think that 304 stainless in an aluminum housing "should not be a serious issue in regards to corrosion". They did say that the aluminum would corrode before the stainless does. They could not see any problem with this combination in a brake system...

Can you post a picture of the engine from the top down where we can get a good view of the metal line in the way?

That would be really neat if we could all meet up.

I've not been able to find out what kind of aluminum yet. That part is included in the 5 ton rebuild kit. I think it is cast aluminum.

I did too. I think mine is around 450-475. Have you adjusted the valves to spec?

Good info. I definitely want to research this out before I make any. Maybe chrome plated carbon steel is our only option.

Wish I would have known about this in 2003. We shot up a bunch of those tanks. I could have been rich when I came home. :doh:

Let me know what parts you need and I will see what I have and what I can fit in the Expedition.

What RPM are you idling at? Sounds weird but my truck did that when it was idling too fast and I set the timing at the faster speed. Try slowing it down and then set the timing. The TM says idle is supposed to be 375 rpm.

Looks like we have enough interest in some of these. I will start figuring out material cost, etc. One thing I don't know is if stainless will react negatively with the aluminum housing these power pistons thread into. I don't think it will be an issue, but I want to research it a little more. I...

How soon are you guys talking about meeting? I might be up visiting 1944mb in July.

I am still fighting mine a little. All of them were rebuilt again last July and only one of the 6 wheels is still leaking. I blocked off the brake line going to that wheel until I can have a chance to tear it open again. Work and other things have not let me do the things I want to do lately. A...

Show this article to the wives gentlemen. We need to buy more military vehicles. http://www.foxnews.com/world/2017/04/09/tanks-bullion-man-finds-gold-bars-buried-in-military-vehicle.html