3" Exhaust for HDJ80

[railswitcher]

I just installed a 3" stainless exhaust I imported from Beaudesert Exhaust Australia . It came complete with a 3.5" dump pipe,high flow muffler,resonator and fit on all the original hangers . It was some what expensive ;$2000 landed; but the difference in performance is well worth it. The turbo runs much cooler; 600F as compared to 1200F; on some of steeper hills here in British Columbia. The truck gets up to highway speed quicker and seems to use less fuel. I haven't refueled since putting the system on. I should mention I also put a snorkel on at the same time . On a run back to the Okanagan from Vancouver ,with about 1000lbs.in back ,I maintained 100KMH even on the hill up to the Hope Slide.I usually do 80KMH up that hill,but boot down a number of times and the EGT gets up to 1225,this time it reached 600. If there are any other HDJ80 owners interested in this system I do have pictures of the system out of the box and the list of parts . I should also mention the Aus. dollar is worth about 90cents Can. so some money is saved there. I would call this very positive and satisfying experience.

[canucksafari]

Originally Posted by railswitcher

It was some what expensive ;$2000 landed; but the difference in performance is well worth it.

Not to rain on your parade but $2000 for an exhaust (not including intallation) is not something i would consider being well worth it in terms of perfomance. IMO, a domestically built exhaust (for far less $) and the addition of an intercooler would have given you much more zoom for the dollar. But then, I'm a person who is quite content to go up the slide hill at 60-80 kms/hr. Also, I was not aware that a bigger exhaust alone could drop your EGTs by 600 degrees.

[83bj60]

Hear, hear! I'd like to see some fuel conusmption figures, and an average EGT over several months. That would be much more reliable.

But at the steep prices fuel is selling now, that $2,000 railswitcher so matter-of-factly spent may indeed well be, in reality, "money well spent"!!!

Have you guys figured out by how many thousands your fuel bill will increase this year just from the rise in Diesel prices?

GAW!!!

[canucksafari]

A short regular 3" exhaust pipe strait out behind the front wheel would have done as good of a job opening it up to breath as a $2000 SS full lenght system for a fraction of the cost. But each to their own. If he turned up the fuel to get more hp, he may have zoom up the hills but his economy just disappeared. The extra energy (BTUs) has to come from somewhere.

[railswitcher]

To reply to Canucksafari . Putting a larger tailpipe on would do nothing for the turbo as the pipe is crushed by Toyota where it passes over the rear axel. This is done apparently to limit the horsepower in the HDJ81 . The muffler is also restrictive. There is no dump pipe available for these units in Canada or the States and therefore you are stuck with stock 2.5 one. This setup follows the stock exhaust pattern , therefore no welding and has a 3.5 dump pipe allowing the turbo to spool faster and run cooler. No need to turn up the fuel . More air coming in and the exhaust leaving unobstructed allows the turbo to give more consistent power.

[canucksafari]

I have heard about them before on Outerlimits, 4wdaction and Patrol4x4. They do have fine exhaust systems and have made a name for themselves in Australia. Some of it they build themselves and some of it like any business is outsourced. However, my point is that any decent custom exhaust place here in Canada should be able to build a similar set-up for a lot less - dump pipe and mandrel bend exhaust. For reference purposes, here is their web page: www.beauexhausts.com.au . Also, I've read that the dump pipe can be had from them for $175 AUS (shipping extra). Probably the cheapest component to ship. The rest is fairly simple for any exhaust shop to put together. It would have been interesting to see some before and after dyno figures. If you get a chance to dyno it, why don't you post the results so they can be compared with those on a stock exhaust system. I have heard claims of a 20% increase in HP with their exhaust but no one ever posted before and after dyno results.

[motorcoach123]

Originally Posted by railswitcher

If there are any other HDJ80 owners interested in this system I do have pictures of the system out of the box and the list of parts .

railswitcher
I would be interested in seeing those pics...did you compare/consider that Aussie system with the Japanese ones that are available?
I am considering the 3" ss system that is advertised on YahooJapan regularly, its about $CAD1000 or so (FOB Japan, plan on carrying it home with me)....not sure if their system includes the larger dump pipe or not.

Cheers
Gord

[83bj60]

Seriously, guys, you really just need a good free-flow or flow improving muffler (if that, even!) and the shortest and widest SS pipe you can get. railswitcher is right about the crushed pipe above the rear exhaust; the OEM system is very restrictive. ANY decent local mod to 3" mandrel bent should bring noticeable improvements. Since my exhaust has broken at the flex joint (noise level is only noticeable when the engine is cold, BTW), my idle has increased from 800 to just above 1000 RPM.

[Martin White]

I wrote about this a long time ago, but when I had a full 3" exhaust installed on my truck, the difference was dramatic in terms of power, from idle to heavy throttle. It felt like a different truck. I didn't notice any increase in fuel economy, as Wayne stated would be the case, but the driveability of the truck was so much better, it was worth it. Unfortunately with the price of fuel, oversupply of these trucks and no sign of either slowing down, it seems most of the money put into mods is going to be lost, so trying to reduce the cost makes sense. I think removing the crimp in the factory exhaust is well worthwhile if nothing else is done, and that could probably be done for very little. It would be interesting to see a dyno result of this before and after.

[83bj60]

Hey Martin, glad so see you here! I guess you made a smart business decision selling before the price of diesel hit the stratosphere How's driving that little car of yours? Smiling all the way to the pump I imagine

I'm still averaging around 11- 11.5l/100 with my truck driving carefully, but I've reached as much as 15 once last winter. Fuel consumption is markedly higher when the truck is cold... Hence the importance of engine preheating...

I can't say I've noticed a big difference in power after my exhaust broke at the flex joint. I don't have any more power at the top end than I had before, it still feels like it doesn't want to go much more than 150kph.

I would say to anyone attempting to mod their exhaust in the hope to gain power or fuel economy to disconnect their existing system at the flex joint and see if that makes a difference... But I believe it will make a difference IF your system is set for power at the injection pump!

[Granite Grinder]

I think if you want a custom 3" SS exhaust that is a bolt in, then this is a good deal.
GG

[railswitcher]

I did check locally for a 3" mandrel bent exhaust in mild steel and the only exhaust shop I could find to do it wanted $1800 with a generic high flow muffler. He could not provide a dump pipe. I hope this ss system will last the life of the truck and on the highway it is as quiet as the stock . I am going to try and attach the pictures I took once I unpacked it. In the packs are the new gaskets and hangers. I should also mention that Steve at EVI Cruiser Parts is looking into importing the system , so if anyone is intested they could possibly get it cheaper through him. I do go to the lower mainland every couple of months if anyone would like to see it installed. My email address is switcher1951@yahoo.ca . I wouldn't mind meeting up with other owners and seeing their rides.

[railswitcher]

Well that didn't work. I will try again.

[Towpack]

My stock exhaust is on it's last legs and reading some of the above comments I'm seriously considering a 3" SS system.We have an exhaust specialist fabricator here in my home town who say they can build sytems for anything from a small car to a full size truck but I'm not so sure about the front down pipe with the flex joint.Is this what you guys are calling the dump pipe? Engine is 1HD-FT.

[Tapage]

I'm running a 3" short exhaust that go out just ahead or the rear wheel and I'm very very pleased .. straight pipe loud for sure .. and drop the EGT at least on 200ºF

Also I notice with this setup and snorkel I can see the overboost light in my dash ..

[83bj60]

WOW, railswitcher, that's a fantastic looking system. Best I've seen so far! Spendy, but certainly looks perfect!

If it could be had for $1,000, it would sell for sure. If loacl custom shops can do SS systems for $500, I'm sure something of that quality could be be done for around $1000. The price you paid takes into account that Australians earn in average much higher than Canadians plus the tremendous shipping and import fees. How much was that in the total cost?

[railswitcher]

In reply to Towpack ,the dump pipe is attached directly to the turbo and the down pipe attaches to it. It is the second picture;the pipe by it self with the bag of parts.

[railswitcher]

For 83BJ60 here in the lower mainland to get a mild steel mandrel bent system was $1800 with a generic high flow muffler,I would hate to see what ss cost. As far as I know there is only one shop here that does mandrel bending and for 3" he is expensive. The total cost out of Australia was $1725 including air freight, Tax was $225 and Brokage fee was $45. I agree that you can get a domestic ss system for around $500to $1000 depending on the grade of stainless. I think this system is better then average grade and it it fitted for this truck. You get the oversize dump pipe.the resonator and the high flow muffler and everything is stainless. I am happy with it and consider it money well spent.

[83bj60]

I must admit that considering some folks are spending over $1000 in your neck of the woods for a regular steel mandrel bent system that has to be welded together from many small parts, your system looks tremendous in comparison.

Although I could never justify that kind of money (I would seriously reconsider the OEM design before I would cnsider a full system like yours, and I don't have that kind of money anyway), I must admit that what you have shown us definitely looks like its worth it.

In other words, the top of the line. Congrats!

[Tapage]

Can you provide us the web where you founf / buy the complete exhaust .?

[Mud_Guppie]

I have several systems coming in. If you're interested in one, please contact me direct
1-877-299-3540
sorry, no star yet

[lshobie]

I'd be interested in one of those down pipes - looks nice.

Louis

[canucksafari]

Originally Posted by lshobie

I'd be interested in one of those down pipes - looks nice.

Louis

Originally Posted by canucksafari

I For reference purposes, here is their web page: www.beauexhausts.com.au . Also, I've read that the dump pipe can be had from them for $175 AUS (shipping extra). Probably the cheapest component to ship.

See above.

[Towpack]

Ordered a 3" SS exhaust system today from the local exhaust specialist.Looking at some of there work the quality is superb.They give 25yr guarantee.I've gone for a system with a side exit just forward of the rear wheel.Apparently the system cannot follow the same route as the OE as it will not fit between the floorpan and the chassis member where the system crosses the back axle without much more extensive fabrication of some sort of wide flat pipe section which would add a lot to the cost and not be as effective.I guess this is why the OE system is flattened out at this point.

The only other option was to route the pipe either between the axle and the body or underneath the axle itself,either way it would be more prone to damage.A side exit can be fitted and still keep 90% of the ground clearance.It gets fitted thursday.

Exhausts UK Custom Stainless Steel Exhausts

[lshobie]

Thanks for the link.

Here is my system, I bought the 3" mandrel bends, SS304 or 309 IIRC, I thne cut it and tack welded parts of it, then brought it in to a shop for TIGing. I used an Aeroturbine muffler. Sounds great, nice and quiet at most times, when hammering it sounds like a champ.

YouTube - HZJ79 turbo aeroturbine landcruiser

[83bj60]

Boy, if only driving to your place didn't cost $100 for the round trip, I'd come visit much more often

How much did the Aeroturbine muffler cost? What do you think of Magnaflow?

[lshobie]

I think I got it for 170 on ebay. No idea about magnaflow - like the looks of the aeroturbine better though

[83bj60]

Yes, from the design schematics I had a glimpse of, it would seem it may be a better design. However, sound wise it would be very difficult to dfifferentiate between that and the Magnaflow. I downloaded sound files that are very, very similar bewteen one another on the same vehicle, and figures show a very noticeable increase in engine output when using this muffler.

I got