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Exhausting All Possibilities - Corsa Performance Exhaust
Better Sound, Better Flow with dB Performance Exhaust by Corsa
From the April, 2012 issue of 8-Lug
Author: Ron Fresquez
Photography: Ron Fresquez
John Stachlewicz, a Ford truck enthusiast and proud owner of an ’11 Ford F-250 crew cab 6.2L XLTSuper Duty, decided to accessorize his truck with a new cat-back system from dB Performance Exhaust by Corsa Performance Exhaust.
“The new exhaust gives the truck that deeper rumble I was looking for without being over the top. When I stomp on the throttle, the system really wakes up and growls. The sound when starting out is just enough to grab your attention but is quiet as the stock system while cruising,” said Stachlewicz.
John Stachlewicz wanted a better sound and more flow out of his Super Duty exhaust.
Sound isn’t the only benefit of adding a performance exhaust system. Flow bench testing from dB by Corsa shows the single, side-exit system flows 32 percent better than stock. Available in multiple configurations to support all cab and bed sizes, the dB exhaust systems feature a mandrel-bent, straight-through design for maximum airflow with no interior drone.
The answer to John’s desires...
The answer to John’s desires was a system from dB by Corsa.
A 5-inch slash-cut tip—laser-etched with the dB by Corsa logo—was added to Stachlewicz’s F-250 to finish off the exhaust installation. “The tips’ exceptional design provides the style and roar truck enthusiasts crave combined with the durability Super Duty trucks require in a rugged environment,” said Stachlewicz.
Although having a professional installer outfit your truck is recommended, the exhaust install can be performed with some standard tools, the use of a hoist, and the help of a friend. Read on to see how this F-250 transformed into a head-turning Super Duty truck.
01. The first step was to...
01. The first step was to loosen the clamp nearest to the inlet of the factory rear muffler using a 15mm socket and ratchet.
02. Next, we unbolted the...
02. Next, we unbolted the rear muffler hanger mount from the chassis using a 10mm socket and ratchet.
03. Then, we unbolted the...
03. Then, we unbolted the rear tailpipe hanger mount from the chassis using a long extension. We used a 10mm socket and ratchet for this step.
04. We removed both of the...
04. We removed both of the front tailpipe hangers from the rubber isolators on the hanger mounts using a grommet puller. The use of a soapy water solution may aid in the removal and installation of the hangers in the rubber isolators.
05. We carefully removed...
05. We carefully removed the entire rear section of the stock exhaust system from the vehicle by separating it from the clamp joint that was loosened in Step 1 and moved it forward, down past the rear axle. The stock exhaust was removed as one piece and was fully intact.
06. With the stock exhaust...
06. With the stock exhaust section on the ground, we removed the factory muffler and rear tailpipe hangers from the rubber isolators on the hanger mounts using a grommet puller. We made note of the position and orientation of each hanger mount. We set aside the muffler and tailpipe hanger mounts and the retaining nuts and bolts because they were all reused during the installation process.
07. Now begins the installation...
07. Now begins the installation of the dB Performance exhaust by Corsa. It is very important to align all the clamps so the open edge of the clamp bracket is parallel and aligned with the notch in the pipe, and the outside edge of the clamp bracket is approximately 1⁄8 inch from the end of the pipe expansion. Failure to properly position or orient the clamps could result in a weak clamping load, or even a potential leak at the clamp joints.
08. First, we removed all...
08. First, we removed all the exhaust system components from the shipping carton, including the three supplied clamps. We located the dB Performance muffler assembly, the supplied 3-inch clamp, and the muffler hanger mount, along with the two 10mm mounting nuts (which were set aside earlier during the removal process). We inserted the muffler hanger into the factory muffler hanger grommet. Note the proper orientation of the muffler hanger mount as shown in the figure.
09. Next, we slid the 3-inch...
09. Next, we slid the 3-inch expanded end of the muffler inlet pipe onto the factory intermediate pipe. Soapy water helps with this step.
10. We then aligned the hanger...
10. We then aligned the hanger mount with the mounting holes in the chassis and secured it with a 10mm socket and ratchet.
11. Next, we torqued the...
11. Next, we torqued the 10mm nuts to the factory specs.
12. We secured the muffler...
12. We secured the muffler in place with the supplied clamp as shown, using a 9⁄16-inch socket and ratchet, making sure to only tighten the clamp nuts just enough to hold the muffler on the intermediate pipe. Note the position and orientation of the clamp.
13. Then we located the front...
13. Then we located the front tailpipe assembly, and one of the supplied 4-inch clamps. We slid the expanded end of the tailpipe onto the outlet of the muffler.
14. We inserted both front...
14. We inserted both front tailpipe hangers into the corresponding rubber grommets. Once again, a soapy water solution was an aid in the installation process of the hangers.
15. Next, we secured the...
15. Next, we secured the front tailpipe in place with the supplied clamp as shown, using a 9⁄16-inch socket and ratchet, making sure to only tighten the clamp nuts just enough to hold the front tailpipe on the muffler.
16. We located the rear tailpipe...
16. We located the rear tailpipe assembly, the supplied 4-inch clamp, and the tailpipe hanger mount, along with the two 10mm mounting bolts (set aside earlier in the removal process). Next, we inserted the tailpipe hanger into the factory tailpipe hanger grommet. Note the proper orientation of the rear tailpipe hanger mount.
17. Our next move was to...
17. Our next move was to slide the expanded end of the rear tailpipe onto the outlet of the front tailpipe. Then we aligned the hanger mount with the mounting holes in the chassis and secured it with a 10mm socket and ratchet and a long extension.
18. We rotated the rear tailpipe...
18. We rotated the rear tailpipe assembly until the rearmost section of the pipe was horizontal.
19. Then we secured it with...
19. Then we secured it with the supplied clamp as shown, using a 9⁄16-inch socket and ratchet.
20. We made sure to only...
20. We made sure to only tighten the clamp nuts just enough to hold the rear tailpipe on the front tailpipe.
21. Now it was time to locate...
21. Now it was time to locate the dB Performance 5-inch slash-cut tip assembly, which has a clamp built into it. We slid the clamp end of the tip onto the end of the tailpipe. The idea is to rotate the tip until the dB Performance logo is centered on the top side of the tip. We snugly tightened the clamp using a 15mm socket and ratchet, making sure to only tighten the clamp enough to hold the tip in place on the tailpipe.
22. Finally, we visually...
22. Finally, we visually inspected the exhaust system position, tip alignment, clamp orientation and position, and exhaust pipe clearance. We made a few adjustments at the slip joints. The best way to do this is to start at the front of the vehicle and tighten the nuts on the three supplied clamps. We torqued the nuts on the clamps to 35 ft-lb. Finally, we tightened the clamp that is built into the tip to 45 ft-lb. It is strongly suggested that all clamps be checked and re-tightened (if necessary) to the recommended torque after initial road testing of the vehicle, as thermal cycling has occurred on the system. Please wait until the system has fully cooled to perform this step.
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