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Ummm…..more difficult than originally thought. First, I went out Sunday to get started. First thing was moving the truck over to my project stall. I don’t remember what got me under the truck, but when I did get under there I noticed I had more issues than just the downpipe - there was exhaust...

I’m going to mockup the core support and inner fender, plus put the AC line in place so I can truly see what my envelope is and then optimize the downpipe to fit. I’m still shocked how tight it is. I think the way I did the #8 tube ate into my space more than I understood.

Got the cab on today. Took longer than I anticipated, but the task is done. Unfortunately I found that the downpipe hits the cab - even when it’s detached from the turbo. I thought I was going to have tons of room with where I put it and have the best heater hose situation I’ve ever had, but...

I’d really like to have the hot side coated in this stuff, but it isn’t cheap so I’d need to make sure my design all works how I want before I make that investment. If I am happy with it, I could blast the stuff and send it to them or make a new setup and send it to them for coating. This way I...

I’d like to wrap them, but the old manifold was rusting under the wrap so I didn’t want to promote that happening again.

The crossover isn’t any lower than the diff skid plate so it’s ok. The pics are deceiving.

I sandblasted the manifolds and hit all the welds on the rest of the pipes with a stainless wire wheel. After that I painted the manifolds, crossover pipe, down pipe and resonator/muffler with KBS Xtreme Temperature Coating. And finally I wrapped the crossover and downpipe with DEI header wrap...

This evening I loaded the chassis up and took it to a local cruise-in, just for funsies. Also had to pop the hood on the Tahoe.

Remote oil filters are installed. I used a Canton remote oil filter adapter and Fragola -10 AN lines and fittings. I bought the oil filter mount a while ago and can’t remember the brand.

Expires October 17th 315164357253246176

It took 2 days, but I finally have the post-turbo exhaust done (mostly). I installed an FTE Diesel muffler/resonator on it again because the sound was great and I had zero drone in the cab. It’s 409 stainless. All tubing is 304 stainless. I started TIG welding all the joints. Oof. That...

As long as I make my cuts straight, it won’t be bad to replace them in the future if the need ever comes.

Yeah, I’m wrapping the crossover and also the starter.

The brace easily fits…..which means I will have room for trans lines as well.

And now I’m just realizing I don’t have the brace between the inspection cover and motor mount installed. I wonder if that is going to clear…..

Actually, I bet if the torque converter inspection cover was removed, the starter can be dropped. I can’t remember if you can drop the inspection cover with a factory-style crossover.

Probably, but with v-band clamps, removing the crossover is a breeze. I did knowingly make some compromises with this design in order to simplify the path of gases into the turbo manifold.

Thanks! I would have liked the TIG welds to turn out better, but I don’t do it often enough to keep my skills up to snuff.

Got the crossover made today. I used some stainless tube I bought off of Amazon that is supposedly 304 - in the end that doesn’t really matter too much because I MIG welded the flex joints and my TIG welds are definitely sub-par. The routing is what I had in mind, so I’m happy with that. I’ll be...

Looks great! I thought you said you were bad at CAD????