My Homemade Exhaust Brake - Dodge Cummins Diesel Forum
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post #1 of 114 (permalink) Old 05-13-2012, 11:57 PM Thread Starter
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My Homemade Exhaust Brake

Ive been driving a Cab Forward truck for about 8 years and Ive grown to love its exhaust brake. So when I finally got my own diesel, it was a must.
My list of materials
4" pipe sch 40 $3
3/8 plate / flanges $10
3/16 plate / baffle $3
3/8 cold roll / shaft $ 2
3/8 ID 1/2 OD bronze bushings for shaft / hardware store $4
.050 copper sheet / gaskets $15
#10 stainless button head screws / bolt baffle to shaft $2
Bimba 4" stroke air cylinder / ebay $20
660 raptor clutch spring / pressure relief
Misc flat bar, sheet metal $10
7/16 bolts / for flanges
1/4 WeatherHead air fittings / 1/4 air hose x 1/4 pipe / napa $16
1/4 air hose / napa $4
2" liquid filled 100 psi gauge / to confirm back pressure $9

Electric side of it:
ARB air compressor / its an older one I had spare $50
Mac air solenoid / for actuation / ebay $25
Sintered Air muffler $3
Micro switch / for throttle pedal / radio shack $4
12v switch / waytek $5
12v relays / 2 $8
16ga wire / lots $16
wiring connectors / lots $5
heat shrink / HF $2

So I didnt cover every piece, but you get the idea.
Here it is completed. To follow will be the build
I put the air cylinder on the down stream side, hoping it will see less heat.


My starting materials and marked baffle


Baffle cut and fit, finished on belt sander.

Flat sided the shaft and drilled/ tapped the holes


Torched the flanges and welded them on. Clamped to try to keepem flat


Baffle installed

Pulled baffle and bushed the shaft.





This shows the proper way to lube a bronze bushing.Place your finger under opening, fill with oil, cap with other finger and apply pressure. The oil will seep through the sides and permeate it with oil.


I designed a pressure relief valve with a series of holes sealed by a small metal disc(hole saw leftovers),Seated by a spring. I experimented with the springs by building a small air chamber, with a relief hole covered by the disc, I varied pressure against the spring with my hydraulic press to find a acceptable pressure.



Then a mount for the air cylinder




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2005 2500 Laramie QCSB, S&B Intake, Exhaust,Smarty S-06POD, ATX wheels.DODGE PIC

Last edited by 44newman; 05-14-2012 at 01:30 AM.
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post #2 of 114 (permalink) Old 05-13-2012, 11:58 PM Thread Starter
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And the lever



Some finishing touches, Weld. Then Powder Coat/ thanks to Harbor Freight


Had some copper laying around, so I gaskets with it.



Install Pics
Wiring was done using the ECM bypass Mech wiring instructions published by PAC Brake.










Thanks for looking

TOYOTA ROCK CRAWLER BUILD 95' X-cab 4.3 Vortec, duals, SAS, CUSTOMhttp://www.pirate4x4.com/forum/showthread.php?t=657455
2005 2500 Laramie QCSB, S&B Intake, Exhaust,Smarty S-06POD, ATX wheels.DODGE PIC
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post #3 of 114 (permalink) Old 05-14-2012, 12:30 AM
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What do do think it cost you material wise?

2003 Quad cab, long box, dually 4 x4 Cummins 5.9 HO Auto 48RE B & W flip ball gooseneck hitch, Samrty Junior.
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post #4 of 114 (permalink) Old 05-14-2012, 01:44 AM Thread Starter
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Quote:
Originally Posted by b1mmuo27 View Post
What do do think it cost you material wise?
I added some prices to most the materials.

It totals $216

Now thats not counting a few nuts and bolts , and a few of those things I bought a while back so they might be a little more expensive now.
Most my steel was bought a couple months ago, I buy it as rems for $0.50/lb
And I found the ARB compressor on craigslist for $50/ Steal.
And not counting consumables or elec, ect. Which wasnt much.
I spent couple evenings after work building the brake, an hour or two at a time.
Then a pretty full day wiring. And about a 1/2 day mounting the brake, air lines, and valve.

TOYOTA ROCK CRAWLER BUILD 95' X-cab 4.3 Vortec, duals, SAS, CUSTOMhttp://www.pirate4x4.com/forum/showthread.php?t=657455
2005 2500 Laramie QCSB, S&B Intake, Exhaust,Smarty S-06POD, ATX wheels.DODGE PIC
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post #5 of 114 (permalink) Old 05-14-2012, 02:11 AM
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NICE job!!!
It's alwyas great to see that level DIY fabrication AND ingenuity.
I particularly like the back pressure valve design.
If you wanted to, I have no doubt that you could give PacBrake a run for their money...LOL.

Gonna post a link to this onto TDR if that's OK.
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post #6 of 114 (permalink) Old 05-14-2012, 02:25 AM
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Thats awesome! how is she out on the road? and how close to the turbo is it mounted(looks lik its next to the transfer case, does the distance affect it)?

2006 Dodge 5.9 Cummins Bighorn, K&N intake and filter, 5" exhaust, 2" leveling kit, isspro gauges, blacked out headlights

Last edited by Klickster102; 05-14-2012 at 02:27 AM.
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post #7 of 114 (permalink) Old 05-14-2012, 02:32 AM
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This is badass , nice work.
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post #8 of 114 (permalink) Old 05-14-2012, 03:02 AM
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Wow!! Extremely creative! How effective is it compared to a big name eb? Makes me wanna go build one right now! Definitely gonna keep this thread in mind for later down the road.


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post #9 of 114 (permalink) Old 05-14-2012, 03:38 AM
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Awesome, I've been collecting parts to build one myself. I'm also curious how well this works braking wise. How much pressure doe it build up?

Yes i can reach the beer fridge from here
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post #10 of 114 (permalink) Old 05-14-2012, 11:24 AM
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Leave it to a Pirate to show everyone up on the Fab work. Nice job. One finger salute.

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post #11 of 114 (permalink) Old 05-14-2012, 02:32 PM
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Pretty awesome. Really like it. I am curious if it is set up to be fully closed at 90* in the pipe or at 67.5* with a bevel grind? Hard to see, just curious if soot hang up will be an issue. Really nice work, Real nice.

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post #12 of 114 (permalink) Old 05-14-2012, 09:54 PM
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Very nice.

Now if I just had a welder.

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