New Muffler

[barmcd]

The PO replaced everything from the engine to the muffler with stainless steel, but couldn't find a OEM muffler so he left the old muffler and tailpipe. I bought a stainless steel Aero muffler and a few elbows and a chrome tip to replace the old, rusted out muffler. Today I finally got around to working on the replacement.

About ten minutes was all it too to get this out from under the coach.



There were two of these securing the muffler to the coach.



These are the stainless steel parts I bought.



I've ordered two of these 6" band clamps to secure the new muffler to the frame.



The issue is that the new muffler is not only much shorter than the stock, but the clamps that fit it have mounting holes that are much closer together than the stock clamps. I intend to use a piece of sheet steel as a bridge--I'll drill holes in it to fit the stock 11" clamp locations, and then holes to fit the new 6" clamp.

That should provide a secure mount and I'm also going to use these to hang the tail pipe from the muffler to the tip.



The original didn't have any hangers, but it was welded all the way out and I'm using clamps to hold the pieces together.

[MSHappyCampers]

Nice job Dennis! What does it sound like?

[onechaddude]

Originally Posted by MSHappyCampers

Nice job Dennis! What does it sound like?

Yes it will definitely look much better. I'm also very curious to the sound. I've been considering an Aero muffler myself. Just waiting on my factory one to take a dump. Shouldn't be too long now LOL.

Chad

[RamiDav]

Dennis

I installed an Aero muffler along with all the pipes much the same as you are doing .

Since you didn't show any clamps in the picture I am posting a picture of the type
I used .
These are so much better than the old type that its not worth saving a few bucks.
A truck shop suggested that I wrap the joint with aluminum foil first which I did to
help guard against leaks , no leaks so far .

Ray

[barmcd]

Originally Posted by MSHappyCampers

Nice job Dennis! What does it sound like?

I'll let you know in about a week Joe.

[barmcd]

Originally Posted by RamiDav

Dennis

I installed an Aero muffler along with all the pipes much the same as you are doing .

Since you didn't show any clamps in the picture I am posting a picture of the type
I used .
These are so much better than the old type that its not worth saving a few bucks.
A truck shop suggested that I wrap the joint with aluminum foil first which I did to
help guard against leaks , no leaks so far .

Ray

Those are what I'm using Ray.

[jleamo1]

Keep us posted on the sound. I replaced our stock muffler with a Magnaflow, it has a throaty sound, not too loud. I almost bought the Aero muffler.

[barmcd]

Originally Posted by jleamo1

Keep us posted on the sound. I replaced our stock muffler with a Magnaflow, it has a throaty sound, not too loud. I almost bought the Aero muffler.

I will. I bought the piece of steel I'll use to interface the old mounting bolt holes with the holes in the new mounting brackets I ordered. The brackets should be here Thursday. I don't anticipate it taking more than a couple hours to line everything up and drill the holes to mount the muffler.

[10Boomer]

I'll following your project: may do this upgrade in the future. I have 400ISL with side exhaust. Thinking not one of these coaches are the same.

[spsm]

Had an areo on my 99 Dutchstar and loved the sound. Went the straight pipe route on my Mtn. Aire, and I love that sound also. Believe me, they know your coming and going. Gas mileage ? Nothing to crow about.

[jimbo2013]

3 years ago I installed one on my 2000 HR w/330 Cat, loved it, a hair louder but very acceptable.

there was a MPG & power increase, when my Newmar needs a replacement it will get an Aero




.

[RamiDav]

When I first installed my Aero I thought it was a little loud but
as time went by I actually enjoy it .
I can't really hear it when driving so some time I open the window
in a tunnel or beside a wall to enjoy the deep rumble sound .

Ray

[distaff]

Originally Posted by RamiDav

When I first installed my Aero I thought it was a little loud but
as time went by I actually enjoy it .
I can't really hear it when driving so some time I open the window
in a tunnel or beside a wall to enjoy the deep rumble sound .

Ray

Ray,

What kind of engine do you run? I'm thinking about a muffler change but I run a C13 with an engine brake (i.e. Jacob's brake - not an exhaust brake) and I'm a little concerned that I currently can use it in developed areas because the muffling is very good.

[jleamo1]

We have the Cummins ISL 400 with a compression brake and 5" exhaust. here is the muffler I installed;
7" ROUND 12774


Here is the finished product, I put a 6" tip on it. it had a 90 degree that stuck out 18" when we bought it, looked strange.