Homemade Exhaust Brake

BigT18 · 01-07-2009, 05:59 PM

I was thinking about makin an exhaust brake and was wonderin if anybody has done it. From the looks of it, it doesnt look very hard. I have a friend who owns an electric motor repair/sale shop so i can pick up a, 12v electric valve and just mod it with a 3" flapper. Then just mount it in the pipe and wire in a switch on my shifter. This seems to easy, is there somethin i'm missing? I'll get some pics and a detail list of how to make it when i build it tomorrow.

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

countrycummins99 · 01-07-2009, 06:01 PM

i was thinking about this to there must be something more complicated because their really expensive to buy

__________________
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 277,539 no crack

BigT18 · 01-07-2009, 06:25 PM

Yeah, i was lookin on eBay and the cheapest one i could find was a couple hundred dollars. I figure i wouldnt cost me more than $20 and a few hours. I might even get fancy and use like a brake light switch on the accelerator in series with a regular switch. That way when i'm cruisin down the highway, i can just leave the switch on and whenever i let off, the exhaust brake will come on. That's be pretty slick i think.

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

countrycummins99 · 01-07-2009, 06:27 PM

a i think i might try and make one see how it goes

__________________
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 277,539 no crack

strobel97 · 01-07-2009, 06:30 PM

The key is that the valve needs to be overcome by the exhaust gasses. When the valve closes pressure builds and loads the motor. Then the valve opens and relives the pressure. It repeats this rapidly. Just make sure the 12v motor you use is not to powerful or somthing will have to give.

__________________
97 2500 4x4 5 speed ext long box. 5" FBD Sraight. #11Fuel Plate. Star Wheel Cranked.

ykdave · 01-07-2009, 07:18 PM

^^^

Their is a reason they are so expensive, alot of R+D goes into the design to keep from blowing up your pride and joy

__________________
97 Ram 2500 / 5.9ctd / 5spd / nv4500 / 4x4 / np241
Home made intake and BHAF, Starwheel cranked, no plate, autometer pyro and boost gauges, Dual 4" stacks, 33x12.5 Mud terrains, posi-lok, tons more to come

countrycummins99 · 01-07-2009, 07:20 PM

oh thats why

__________________
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 277,539 no crack

illflem · 01-07-2009, 07:57 PM

Quote:

When the valve closes pressure builds and loads the motor. Then the valve opens and relives the pressure.

The ones I've experienced, probably over a dozen, don't work that way.

The ones I've worked on (Banks, BD and Pac) close the valve at idle. Sensor to control this is on the throttle linkage. There is only full open and closed at idle on the butterfly, no inbetween.
Unless you have 60lb exhaust springs there must be about a 3/8" hole in the butterfly.
Butterflies are vacuum actuated, full vacuum is applied to one side of the cylinder that opens/closes the valve and remains there depending on whether the signal is for open or closed.

I spent much time googling for a source of exhaust butterfly valves and found a source for inlines powered by an electric motor, all stainless steel, up to 6" and all under $200.
Sorry didn't save the link but it wasn't too hard to find.

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

Last edited by illflem : 01-07-2009 at 08:00 PM.

BigT18 · 01-07-2009, 08:21 PM

So your saying if there's a 3/8" hole in the butterfly, then it will release enough pressure to prevent engine damage?

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

illflem · 01-07-2009, 08:44 PM

Quote:

Originally Posted by BigT18

So your saying if there's a 3/8" hole in the butterfly, then it will release enough pressure to prevent engine damage?

Yep.
Think the 60lb springs weren't stock until '97 or '98.
Pac-Brake is the only one that has a hole in the butterfly for people who don't want to install 60lb springs.
They also give you a bolt to plug the hole if you do have 60 pounders.
The others require you change the springs and even include them for more $.

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

strobel97 · 01-07-2009, 08:51 PM

illflem.. Your right.. Im thinking of an engine brake.

__________________
97 2500 4x4 5 speed ext long box. 5" FBD Sraight. #11Fuel Plate. Star Wheel Cranked.

BigT18 · 01-07-2009, 08:52 PM

Sweet, all hope isnt lost. I saw the ones on Pacbrake's website and they had like a wastegate type doohicky. They looked pretty nice, but they probably want an arm and a leg.

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

01-07-2009, 05:59 PM	#1 (permalink)
BigT18 Cummins Enthusiast Join Date: May 2008 Location: CNY Posts: 206 BigT18's Truck Pics	Homemade Exhaust Brake I was thinking about makin an exhaust brake and was wonderin if anybody has done it. From the looks of it, it doesnt look very hard. I have a friend who owns an electric motor repair/sale shop so i can pick up a, 12v electric valve and just mod it with a 3" flapper. Then just mount it in the pipe and wire in a switch on my shifter. This seems to easy, is there somethin i'm missing? I'll get some pics and a detail list of how to make it when i build it tomorrow. __________________ 1995 Cummins 12v Reg. Cab 4x4 5 speed, 250,000 miles, boost/pyro, straight piped 5" stack, #10 plate, pump cranked, coal rollin.

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01-07-2009, 06:01 PM	#2 (permalink)
countrycummins99 Diesel Freak Join Date: Apr 2008 Location: mcadoo pa Posts: 645 countrycummins99's Truck Pics	i was thinking about this to there must be something more complicated because their really expensive to buy __________________ 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 277,539 no crack

01-07-2009, 06:25 PM	#3 (permalink)
BigT18 Cummins Enthusiast Join Date: May 2008 Location: CNY Posts: 206 BigT18's Truck Pics	Yeah, i was lookin on eBay and the cheapest one i could find was a couple hundred dollars. I figure i wouldnt cost me more than $20 and a few hours. I might even get fancy and use like a brake light switch on the accelerator in series with a regular switch. That way when i'm cruisin down the highway, i can just leave the switch on and whenever i let off, the exhaust brake will come on. That's be pretty slick i think. __________________ 1995 Cummins 12v Reg. Cab 4x4 5 speed, 250,000 miles, boost/pyro, straight piped 5" stack, #10 plate, pump cranked, coal rollin.

01-07-2009, 06:27 PM	#4 (permalink)
countrycummins99 Diesel Freak Join Date: Apr 2008 Location: mcadoo pa Posts: 645 countrycummins99's Truck Pics	a i think i might try and make one see how it goes __________________ 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 277,539 no crack

01-07-2009, 06:30 PM	#5 (permalink)
strobel97 Newbie Join Date: Jul 2007 Location: Northfield, Minnesota Posts: 12 strobel97's Truck Pics	The key is that the valve needs to be overcome by the exhaust gasses. When the valve closes pressure builds and loads the motor. Then the valve opens and relives the pressure. It repeats this rapidly. Just make sure the 12v motor you use is not to powerful or somthing will have to give. __________________ 97 2500 4x4 5 speed ext long box. 5" FBD Sraight. #11Fuel Plate. Star Wheel Cranked.

01-07-2009, 07:18 PM	#6 (permalink)
ykdave Diesel Head Join Date: Feb 2008 Location: Yellowknife, NT, Canada Posts: 2,959 ykdave's Truck Pics	^^^ Their is a reason they are so expensive, alot of R+D goes into the design to keep from blowing up your pride and joy __________________ 97 Ram 2500 / 5.9ctd / 5spd / nv4500 / 4x4 / np241 Home made intake and BHAF, Starwheel cranked, no plate, autometer pyro and boost gauges, Dual 4" stacks, 33x12.5 Mud terrains, posi-lok, tons more to come

01-07-2009, 07:20 PM	#7 (permalink)
countrycummins99 Diesel Freak Join Date: Apr 2008 Location: mcadoo pa Posts: 645 countrycummins99's Truck Pics	oh thats why __________________ 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 277,539 no crack

01-07-2009, 08:21 PM	#9 (permalink)
BigT18 Cummins Enthusiast Join Date: May 2008 Location: CNY Posts: 206 BigT18's Truck Pics	So your saying if there's a 3/8" hole in the butterfly, then it will release enough pressure to prevent engine damage? __________________ 1995 Cummins 12v Reg. Cab 4x4 5 speed, 250,000 miles, boost/pyro, straight piped 5" stack, #10 plate, pump cranked, coal rollin.

01-07-2009, 08:51 PM	#11 (permalink)
strobel97 Newbie Join Date: Jul 2007 Location: Northfield, Minnesota Posts: 12 strobel97's Truck Pics	illflem.. Your right.. Im thinking of an engine brake. __________________ 97 2500 4x4 5 speed ext long box. 5" FBD Sraight. #11Fuel Plate. Star Wheel Cranked.

01-07-2009, 08:52 PM	#12 (permalink)
BigT18 Cummins Enthusiast Join Date: May 2008 Location: CNY Posts: 206 BigT18's Truck Pics	Sweet, all hope isnt lost. I saw the ones on Pacbrake's website and they had like a wastegate type doohicky. They looked pretty nice, but they probably want an arm and a leg. __________________ 1995 Cummins 12v Reg. Cab 4x4 5 speed, 250,000 miles, boost/pyro, straight piped 5" stack, #10 plate, pump cranked, coal rollin.