Fabricated and installed exhaust brake, ramps and hitch M923A2

[dirk721]

I just finished up a few more projects in preparation for my Moab trip at the end of the month. Blue Ox exhaust brake with 24v air solenoid that works better than I thought on that big 5 ton! I tested and tuned the back pressure to the recomended 35psi on the 8.3 cummins so i don't float any valves.

I made the hitch all from 3/8" and 1/2" steel and boxed in the 10" wide tube steel base plate for a little extra strength.

I used 3" C-channel and 1/4" 2x2 angle iron for the ramps. The ramps are 13' long and I was still surprised at the approach angle for my M1009 to get up.

 

[gimpyrobb]

Nice addition!

Bjorn(cranetruck) put an exhaust brake on his deuce and said it was a very worthwhile mod.

 

[spicergear]

I gotta look for something like that. Very nice addition and picture #7 (right click, save as!)

 

[dawico]

Very cool. They look good loaded up.

 

[Artisan]

What did you do w/ the rest of the exhaust system?
Got any pics?

 

[DevRev]

Silly question but what do you mean by exhaust break and why are you using an air solenoid? Newbie here

 

[FloridaAKM]

An exhaust brake (not break) shuts the exhaust outlet & allows you to use the engine as a brake on a diesel engine, think mountain roads down hill. The air solenoid operates off the truck air system as it is already available. Now the driver of the truck can use the exhaust brake, commonly called a jake brake, to slow down the truck instead of using the air brake system. Having both systems is an upgrade in the driving experience for those know how to use them.

 

[73m819]

An exhaust brake (not break) shuts the exhaust outlet & allows you to use the engine as a brake on a diesel engine, think mountain roads down hill. The air solenoid operates off the truck air system as it is already available. Now the driver of the truck can use the exhaust brake, commonly called a jake brake, to slow down the truck instead of using the air brake system. Having both systems is an upgrade in the driving experience for those know how to use them.

There will be a manual on/off switch to turn the system on/off, there will be a throttle switch to activate the system for braking, letting off the throttle will bring the exhaust brake on line, restricting the exhaust, which back pressures the engine, slowing it down, and a clutch switch to keep the system from activating when the clutch pedal is pushed. Some exhaust brakes are selectable as to the amount of braking that the system provides (lite, medium, heavy).

 

[cranetruck]

An exhaust brake (not break) shuts the exhaust outlet & allows you to use the engine as a brake on a diesel engine, think mountain roads down hill. The air solenoid operates off the truck air system as it is already available. Now the driver of the truck can use the exhaust brake, commonly called a jake brake, to slow down the truck instead of using the air brake system. Having both systems is an upgrade in the driving experience for those know how to use them.

The exhaust brake is not the same as the "Jake brake". The exhaust brake just closes off the exhaust pipe to increase the back pressure. Think "throttle" on a gasoline engine (diesels don't have one).

 

[Shark Bait]

Nice setup. The rigs look good together. What is the loaded height?

 

[FloridaAKM]

Thanks for the extra clarifications, I missed those details by posting too early in the morning. Not to mention, trying to juggle doing taxes @ the same time.

Can I claim my Deuce as a dependent this year? She is a new addition to the family & requires constant feeding & upkeep ......

 

[Tinwoodsman]

Very nice work!

 

[DevRev]

Thanks folks!

 

[dirk721]

Thanks guys! It has been a fun project truck!

Artisan, here is a picture of the rest of the exhaust. I used the elbow that used to turn up into the muffler to turn the exhaust down right after the toolbox. I had it originally straight piped up with a stack right behind the cab but I couldn't even hear myself think inside the cab at 55 mph! Sounded great, but it was a little loud.


Here is a picture of the solenoid that I used for the exhaust brake that mounted in the battery box.

 

[Ford Mechanic]

The exhaust brake is not the same as the "Jake brake". The exhaust brake just closes off the exhaust pipe to increase the back pressure. Think "throttle" on a gasoline engine (diesels don't have one).

Correct,
A Jake brake actually closes the exaust valves in the head with a disconnector.