It's been a long summer but I still haven't given up. I decided to finally tackle the exhaust now that I had the headers painted. The header instructions said to remove the spark plugs for installation but I couldn't resist putting new ones in with all the room available. It also said to trim the left side engine mount, (which I did). I had to bend the shifter linkage for clearance also. The driver's side headers were installed from the bottom up. Working slowly I cleared the spark plugs althou I mangaged a few scrapes.
I painted the headers with common wood stove paint without much expectations but it has held up surprisingly well. The passenger side headers dropped in from the top without a hitch althou I had to tweak the dipstick tube a bit.
While I was working underneath I decided the useless long rusted out right side tank could come off to clean things up a bit. I have had a filler neck leak for a long time but the smell of gas was way too noticeable and sure enuff the left side tank sprouted a leak. The next day I ordered one up along with the straps. But the support brackets were finished and the fuel pump outlets were in very poor shape too. I scrounged around our wrecking yard and salvaged two brackets. These are from the passenger side and one set had holes that didn't line with the holes on the frame. I drilled out the new locating holes and welded nuts on. After a good sand blasting they ended up looking nice.
These are the pieces that used to hold up the tanks. The salt is brutal here on the roads during winter months.
Here I am test fitting all the pieces together.
Pump installed and all sealed with some paint. The padding is an inner tube I cut up.
Now to address the filler neck. Could not find a new one and the ones in the wrecking yard were unusable. I ordered a new one for a '95 Chevy. Too long but the filler diameter was perfect.
I cut it down and welded a good section of one I found from a donor. One left is the actual neck from my truck. No wonder if leaked when I filled the tank. Not shown here but I did weld the loop that held the grounding strap to my new piece. Painted with the same paint I did the tank with.
Fitting the exhaust took a lot of trial and error but once I got going with the first pieces it came together well. I sliced out sections for the Magnaflow CATS and mounted them as close to the collectors as possible while keeping them close together at the same time. I can live with the left side being offset with the right.
I wasn't looking for performance here but I expected a bit more power with the twin exhaust and headers. Eliminating the original ancient CAT would have been a huge improvement alone I thought but the truck performs exactly the same. At least I don't leave a puddle of fuel behind now.
Althou the truck ran like a champ, a week after I did this work I found the truck could barely start and couldn't make it out of the driveway. Took a lot of digging into and reading but I was stumped. The idle would surge, stumble when given gas and the truck couldn't move itself. I replaced the coolant temp sensor, the MAP sensor, cap and rotor and the injectors. Nothing. My boss came by and scanned it, no codes. But right away he said it was starving for fuel but since I had just installed a brand new pump I knew it couldn't be that. He suggested a fuel pressure test and I bought a pressure tester from NAPA. Sure enough the pump could only manage 8 psi. Picked a nice warm day and down came the tank. The small rubber line on the pump that connects to the hanger assy had come off. Someone installed the hose clamp on the wrong side of the line flare and could only pump enough fuel into the system to start the truck but not much else. Happy to solve that I tested the pressure, 13 psi now. Earlier in my repair attempts when I reconnected the lines to the throttle body I over tightened the line fitting only to snap a huge chunk of the throttle body off. So I had to order one of these:
It was a very expensive fix for something so simple. The bang head icon here doesn't do justice to how dumb I felt when I broke it.
