Homemade Exhaust Brake

[illflem]

Originally Posted by BigT18

I think thats what i'm gonna do. But illflem got me a little worried that i wouldnt be able to use it on any rpm other that idle. If he just means no throttle then im game.

Rpm doesn't matter, only throttle.
When I'm towing 20,000 lbs down a steep hill I'll hit 2k rpm all the time with my brake on.
Nice thing about having a micro switch on the throttle is if you're going down a steep mountain grade with slow corners and fast straightaways you just leave the brake on.
In fact I know people who leave their exhaust brake on all the time and even have it wired so it turns on their brake lights with the exhaust brake so the people behind don't rear end them since they're not using the foot brake.

Not having this simple throttle safety feature is asking for trouble if you space out.

Unless you change your valve springs you'll need to drill a hole in the butterfly.

One more time, check this out, $175 http://www.badlanzhpe.com/page6.html

__________________
Bill
'95 2500 4wd auto
'95 3500 5 speed heavy hauler
Not stock

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Last edited by illflem : 01-08-2009 at 08:48 PM.

[BigT18]

Alright, thanks for the clarification. I've seen the cutouts and they are nice. I'm only $10 in the hole right now. The air cylinders and solenoids are only like $30 on ebay. I'm gonna try makin one first, since its cheap. If my brake fails, then i'll probably buy one of them.

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1995 Cummins 12v Reg. Cab 4x4 5 speed, 250,000 miles, boost/pyro, straight piped 5" stack, #10 plate, pump cranked, coal rollin.

[farmboy1989]

Illflem, have you tryed one of the exhaust valves you are pushing? I am considereing getting something like that. Just wondering if anyone had any actual experience.

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1997 Dodge 2500 3/4 ton ext. cab 4x4 5sp., Dana 80 rear, 3:55 gears, Dual 5 inch stacks, 116,000 miles

[illflem]

Originally Posted by farmboy1989

Illflem, have you tryed one of the exhaust valves you are pushing? I am considereing getting something like that. Just wondering if anyone had any actual experience.

I'm not pushing them, just saw that they were a cheap way to make a brake when I was considering making one myself several years ago.
Don't see why it wouldn't work, the concept is very simple.

__________________
Bill
'95 2500 4wd auto
'95 3500 5 speed heavy hauler
Not stock

[Stiffler98.5]

subscibed

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1998.5 3500,4X4, 5-speed, arp studs, Oringed, 150 gph airdog lift pump, custom cut BIG injectors, .093 crossover tubes, quadzilla adrenaline, twin turbos, south bend dd clutch, bd diesel vp44, 2" leveling kit, 6" black stacks, train horn 600 hp 1134 ft lbs

[BigT18]

I'm waitin on my Bimba pneumatic air cylinder and a solenoid valve. Should be here either tomorrow or monday.

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1995 Cummins 12v Reg. Cab 4x4 5 speed, 250,000 miles, boost/pyro, straight piped 5" stack, #10 plate, pump cranked, coal rollin.

[farmboy1989]

Using the exhaust cutout, you say drill a 3/8" hole I believe. Will my 215 hp 97 12v have the 60 lb exhaust springs?

One of the most important questions, will it make the super cool sound that the big straight piped cats and cummins' make when they turn on their exhaust brake????

__________________
1997 Dodge 2500 3/4 ton ext. cab 4x4 5sp., Dana 80 rear, 3:55 gears, Dual 5 inch stacks, 116,000 miles

[Black_Ram07]

This is just my opinion, but I'm pretty sure that before it did any damage to the engine, it would most likely blow the exhaust apart at a seem or a seal. Also I would mount it as close to the engine as possible like the other guy said, that way it doesnt have to build up pressure in that large of an area.

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2007 Bighorn 5.9, 5" from downpipe to 5" stacks, Edge EZ, BD boost fooler "Why don't ya ask my be-hind! That is if ya can catch it! Whata ya say ta that HYDRO PANTS!!!!"

[countrycummins99]

ISB Improvements over the 12 Valve Cummins TurboDiesel
Information obtained from TDR issues and Chrysler Master Tech No 2 February 1998.

* New piston design features a symmetrical combustion bowl
o (combined with vertical centered injector and higher injector pressures) for improved power, fuel efficiency and oil control
* New vertically housed thermostat is easier to access for service and has fewer leak paths for improved in-cab heating
* New electronic fuel system improves engine control, driving performance, engine cleanliness and provides engine/vehicle diagnostics
* New Bosch VP44 Electronic Fuel Injection Pump has higher injection pressures, electronically controlled timing and fueling for precise, instant control. The pump is driven at half the engine speed by the front gear train to reduce operating noise
* New engine-matched Holset turbocharger is custom-designed for high-speed ratings and wastegated for improved engine performance at all speeds
* New fuel filter has an integral water separator and water-in-fuel sensor. An environmentally friendly cartridge is rated at five microns
* New 24-valve cylinder head produces improved air and coolant flow, more torque over a wider range and improved fuel economy with reduced emissions
* New valve train has wider lobes on the tappet face, on the cam, and longer push tubes.
* To reduce camshaft wear, an electric lift pump eliminates the need for a mechanical lift pump lobe.
* The 60 pound standard valve springs are compatible with engine braking
* New single-piece valve cover allows faster access and easier servicing
* No-adjust overhead has improved lubrication and requires its first check at 96,000 miles to reduce scheduled maintenance
* The EGR valve (CA) and catalytic converter are eliminated.


so 60lbs valve springs were not available until the 24 valves to answer your question farmboy1989

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99 DODGE 24VALVE, FASS 150, EDGE COMP/SMARTY REVO STACK/100HP COALTRAIN STICKS ,BHAF,TC LOCK UP SWITCH 5"MITER CUTS, 3.55 ANTI SPIN ,SMOKE SWITCH, SILENCER RING KILLED, GAUGES (FUEL PRESSURE, TRANS TEMP, BOOST, EGT))INFAMOUS 53 BLOCK 293,780 no crack

[aautio1004]

Most likely not...as the ones you are talking about aren't exhaust brakes, they are engine brakes...they do something with the valves inside the engine..essentially if my hunch is correct they hold shut the valves so that the compression of the engine slows itself down. But they will make a distiquished sound through the exhaust when they are on, but not the really loud "popping" sound like you get on an engine brake such as the Jake brake.

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'01 2500 4x4 QC/SB, 4" straight pipe, Amsoil intake, Autometer gauges,Smarty,Edge Comp Hot,Holley Blue,HX40,Recon roof led's, manual high idle, built up auto trans, 89% stall TC
'07 Chev 2500 CC/LB Duramax LBZ Edge Juice with Attitude

[BigT18]

Close. When you let off the throttle on a diesel, the air in the cylinders acts as a spring and pushes the piston back down, providing little to no braking. A engine retarder, (compression brake, engine brake, call it what you will) opens the exhaust near the top of the compression stroke so there is no spring effect on the piston, theres just resistance on its way up providing braking. The popping you hear is the compression being let out.

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1995 Cummins 12v Reg. Cab 4x4 5 speed, 250,000 miles, boost/pyro, straight piped 5" stack, #10 plate, pump cranked, coal rollin.

[farmboy1989]

I was thinking about puttin it just as the downpipe turned and goes straight down the frame. Thats not too far away from the turbo is it? Does everyone think it will need 1 3/8" hole? Or if it does need holes would 2 smaller ones be better?

__________________
1997 Dodge 2500 3/4 ton ext. cab 4x4 5sp., Dana 80 rear, 3:55 gears, Dual 5 inch stacks, 116,000 miles