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
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