Join Date: Nov 2008
Location: Beautiful Chester County, PA
I contacted Dan to discuss a system and what would work for my needs. While I really wanted Stainless, I could not afford that and chose to paint the Pipes before install. I would highly recommend if you can....to upgrade to the Polished Stainless Tail Pipes. These are part of the system that gets seen the most and they look great.
I got the 2.5" Aluminized System and went with Dan's recommendation and got the Sportsman XL Mufflers and couldnt be happier. While I wanted loudish, I did not want obnoxious. I would compare these to the old FM mufflers as far as noise level but they sound even better when you get on the gas. I'm sure sound will increase a little when I switch out to the Tri-Y's and Dans Cats. I will report back if the noise level is noticeably louder.
While the system fit very well, it does appear to hang a little lower under the car than the FM setup, its a little tougher to get the X-Pipe section to clear the Driveshaft. What I did, was placed Jack stands under the Frame and let the Axle hang as low as it could and kept a 1/4" clearance to the D/S. Then before tightening it all down with the band clamps, I raised the Axle to simulate ride height and make sure all components were clear.
Another issue was with the Driver Side Muffler hanger. I noticed that the one section of pipe was a little too long and would have hit the differencial case as well as the ABS wire. While Dan felt the Band Clamps could be a problem (he recommended welding), I had a feeling they would not interfere and they did not, fit well around the Axle and hold the system together very well.
The band clamps were purchased from JEGS for $7.99 each and you will need 10 of them with his kit. What I did find was as tightening the band clamps, it was tough to get them to tighten as much as I had wanted. I backed off the Nuts a little, put some Antiseize on the Threads and under the Nut. Doing this made it much easier to clamp these things down fully and think the Stainless clamp actually stretches a little for a tight leak free joint. Also, before assembly, I used a little RTV High Temp Red on the slipjoints. Not a lot, just a little coating to help seal things.
The attached pics show the system parts before they were installed and just painted. In the 1 pic, you will see the painted system plus the unpainted Aluminized Tails along side of the Polished Stainless Tails. These tails are very nice and glad I got them. You will also see the Hanger interference and where I cut it off.
Hopefully, this thread will show that you can install a system yourself even if you dont have a lift. I was a little concerned that I could have done a little better alighing the pipes, so within days of the install, I contacted a Muffler shop just to see if on the lift they could do any better adjusting it for more clearence. After they got it up on the lift, he said it looks great and "we really dont see anything that needs adjusted" and complimented me on the install. When it was off the lift, I asked him what do I owe ya....he said "nothing, we didnt do anything". So overall, Thumbs Up to Dan and his ready to install setup.
'95 Caprice SS conversion - Bonny Buckets - 96 Column, Shifter and Console - 3.73 Gear and Herter tune - Z/28 Cluster - Blazer OH Console - Green/Pink bushings - Chromed Impala Wheels - Eibach Springs and Bilstein Shocks - Corvette Engine Dress - the list goes on and still more to do...it never ends.