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  • Custom Dump Pipe 1KZ-TE

    Hey all,
    This week I fabricated myself a 3" dump pipe to replace the OEM cast one, thanks go to MickL for supplying his old one to use as a pattern - so my car wasn't off the road all week . I basically wanted to remove the major restriction the 1KZ-TE motor has in the exhaust system without going to the expense of a whole new system (call me a tight-arse). The bore diameter of the cast one is roughly 1 3/4" and the rest of the system is just under 2 1/2". I was prepared to replace the muffler if needed, but first impressions are that I'm more than happy with the results. This thing now pulls right up to the redline now whereas before you had to upshift just above 3000rpm as there was nothing above that point. It would be very interesting to compare my result with a mandrel bent 3" system fitted - chipped prado on a dyno.

    I made a jig using the cast dump pipe, fabricated a flange from 10mm plate to suit the intermediate pipe including studs and used the turbo housing flange Mick sold me, (I was going to profile cut my own but for $20 why bother?). Used one 135 deg bend and a 90 deg bend (in 3" pipe). The result didn't look too dissimilar to the Beaudesert and Taipan ones available except for being shorter and made in mild steel not stainless. A coat of heat proof paint to combat corrosion and it was a straight bolt in jobby. All up cost me $75 plus my time.
    I did add some brackets to it to refit the heat shield but due to the differing dimensions of the pipes the shield touches the new pipe in one spot and rattles a little, so I think it will be removed in the next few days.
    I will take some photo's tomorrow and post here, though with the benefit of hindsight I should have done that during fabrication and before fitment but I do realise this mod isn't really a handyman's project - there is a bit of skill with a mig welder required and machining of the flange isn't something you can do without a lathe and if you have those skills you shouldn't really need a series of photo's to show you what to do.. 8)


    [edit photo's attached]





    Regards

    Adrian
    Silver '04 KZJ120~Manual~GXL~Dobinson/Kings lift~Custom valved Ironmans~Detroit Locker~Endless Air~X9 Superwinch~Madman EMS1~TJM Dual Battery~Rhino Roof Tray~120W solar panel~Foxwing awning~Bushskinz UVP~Long Ranger water tank~Bushman fridge~Steinbauer P-Box~Beaudesert 2 3/4"~Airtec Snorkel~TJM Sliders~Prico Boost Gauge~BFG-KO2s~TPMS~GME TX3420~Front and Rear Cameras~Ultimate Camper hanging off the back!

  • #2
    Re: Custom Dump Pipe 1KZ-TE

    Hummmm, would you be interested in making some more?

    Andy
    I had mental issues when I owned a Discovery.......But it's sorted now!

    Comment


    • #3
      Re: Custom Dump Pipe 1KZ-TE

      Good work Adrian. Looks very neat and tidy.

      Mick
      [CENTER][B][I][SIZE=1][COLOR=blue]1KZ-TE Turbo Diesel, 5 speed manual, 3.5 inch lift, 265/70/17 Mickey Thompson MTZ, D-Tronic chip, Boost controller, mandrel exhaust, dump pipe, modified intake, ARB steel bar, Magnum winch, Safari snorkel, rear drawers, half cargo barrier, dual batteries, Uniden UHF, Sat Nav, reverse camera, Magellan XL , Tjm bash plates, ARB alloy roof rack, rear telescopic work light and numerous other modifications!!!
      Now with 3BAR MAP sensor & 18PSI Boost![/COLOR][/SIZE][/I][/B][/CENTER]

      Comment


      • #4
        Re: Custom Dump Pipe 1KZ-TE

        Originally posted by Andy_B
        Hummmm, would you be interested in making some more?

        Andy
        Possibly..
        Silver '04 KZJ120~Manual~GXL~Dobinson/Kings lift~Custom valved Ironmans~Detroit Locker~Endless Air~X9 Superwinch~Madman EMS1~TJM Dual Battery~Rhino Roof Tray~120W solar panel~Foxwing awning~Bushskinz UVP~Long Ranger water tank~Bushman fridge~Steinbauer P-Box~Beaudesert 2 3/4"~Airtec Snorkel~TJM Sliders~Prico Boost Gauge~BFG-KO2s~TPMS~GME TX3420~Front and Rear Cameras~Ultimate Camper hanging off the back!

        Comment


        • #5
          Re: Custom Dump Pipe 1KZ-TE

          Originally posted by MickL
          Good work Adrian. Looks very neat and tidy.

          Mick
          Cheers Mick. Thanks again for your help
          Silver '04 KZJ120~Manual~GXL~Dobinson/Kings lift~Custom valved Ironmans~Detroit Locker~Endless Air~X9 Superwinch~Madman EMS1~TJM Dual Battery~Rhino Roof Tray~120W solar panel~Foxwing awning~Bushskinz UVP~Long Ranger water tank~Bushman fridge~Steinbauer P-Box~Beaudesert 2 3/4"~Airtec Snorkel~TJM Sliders~Prico Boost Gauge~BFG-KO2s~TPMS~GME TX3420~Front and Rear Cameras~Ultimate Camper hanging off the back!

          Comment


          • #6
            Re: Custom Dump Pipe 1KZ-TE

            Adrian is the dump pipe the same of the 90 Series? Cause i'm pretty interested.

            ANDY
            I had mental issues when I owned a Discovery.......But it's sorted now!

            Comment


            • #7
              Re: Custom Dump Pipe 1KZ-TE

              I too could be interested if you were to go into production ... We also have to shift at just over 3000 rpm because all it does after that is to make more noise!

              Does the turbo appear to spool up any quicker than previously?
              [size=1][i][b]2004 GXL | Turbo Diesel | Manual | [/b]ARB Deluxe Bar | Safari Snorkle | Dual Batteries | ARB Compressor (mounted under hood) | Brake Controller | Uniden UH-012 UHF | TP09X1 Head Unit | [url=http://www.pradopoint.com/showthread.php?15100-Spoony-s-04-GXL-Turbo-Diesel]My Rig Build Up[/url][/i][/size]

              Comment


              • #8
                Re: Custom Dump Pipe 1KZ-TE

                Originally posted by Spoony
                I too could be interested if you were to go into production ... We also have to shift at just over 3000 rpm because all it does after that is to make more noise!

                Does the turbo appear to spool up any quicker than previously?
                Bits of steel going all over Aust.....

                First, Violets recovery points are scattered all over Aust, and I have a feeling this is going to evolve as well

                Count me in if you looking to knock a few out.....
                Cheers

                Daz

                2004 TD GXL Auto Prado

                Comment


                • #9
                  Re: Custom Dump Pipe 1KZ-TE

                  Me too!

                  The good thing about your design is they are jigged off the original dump so the down pipe is the same as factory.
                  06 GXL TD 5 spd man, Dual Batteries, Safari knock off Snorkel, Sov. Bar, BFG ATs, GME TX3420, Safari Dtronic, ARB Compressor.

                  Comment


                  • #10
                    Re: Custom Dump Pipe 1KZ-TE

                    Hi Guys
                    I'm currently drawing up the flanges in AutoCad and I'll make some enquiries as to the cost of laser cutting some. I'm reckoning around $100 worth of materials + a bit of $ for my trouble for each pipe should cover it. I can't make them too quickly as I don't have a great deal of spare time what with 3 older kids and a 6 month old baby.

                    Bear in mind as well that I have not dyno'd my setup so my results are purely seat of the pants, and if I go into limited production I won't be offering a warranty as to the effectiveness of this mod on the power output of these motors Caveat emptor?

                    Regards

                    Adrian
                    Silver '04 KZJ120~Manual~GXL~Dobinson/Kings lift~Custom valved Ironmans~Detroit Locker~Endless Air~X9 Superwinch~Madman EMS1~TJM Dual Battery~Rhino Roof Tray~120W solar panel~Foxwing awning~Bushskinz UVP~Long Ranger water tank~Bushman fridge~Steinbauer P-Box~Beaudesert 2 3/4"~Airtec Snorkel~TJM Sliders~Prico Boost Gauge~BFG-KO2s~TPMS~GME TX3420~Front and Rear Cameras~Ultimate Camper hanging off the back!

                    Comment


                    • #11
                      Re: Custom Dump Pipe 1KZ-TE

                      Adrian is the dump pipe the same of the 90 Series? Cause i'm pretty interested
                      Identical...
                      [CENTER][B][I][SIZE=1][COLOR=blue]1KZ-TE Turbo Diesel, 5 speed manual, 3.5 inch lift, 265/70/17 Mickey Thompson MTZ, D-Tronic chip, Boost controller, mandrel exhaust, dump pipe, modified intake, ARB steel bar, Magnum winch, Safari snorkel, rear drawers, half cargo barrier, dual batteries, Uniden UHF, Sat Nav, reverse camera, Magellan XL , Tjm bash plates, ARB alloy roof rack, rear telescopic work light and numerous other modifications!!!
                      Now with 3BAR MAP sensor & 18PSI Boost![/COLOR][/SIZE][/I][/B][/CENTER]

                      Comment


                      • #12
                        Re: Custom Dump Pipe 1KZ-TE

                        Originally posted by Andy_B
                        Adrian is the dump pipe the same of the 90 Series? Cause i'm pretty interested.

                        ANDY

                        Sorry Andy - missed that one, thanks MickL
                        Silver '04 KZJ120~Manual~GXL~Dobinson/Kings lift~Custom valved Ironmans~Detroit Locker~Endless Air~X9 Superwinch~Madman EMS1~TJM Dual Battery~Rhino Roof Tray~120W solar panel~Foxwing awning~Bushskinz UVP~Long Ranger water tank~Bushman fridge~Steinbauer P-Box~Beaudesert 2 3/4"~Airtec Snorkel~TJM Sliders~Prico Boost Gauge~BFG-KO2s~TPMS~GME TX3420~Front and Rear Cameras~Ultimate Camper hanging off the back!

                        Comment


                        • #13
                          Re: Custom Dump Pipe 1KZ-TE

                          Originally posted by Spoony
                          Does the turbo appear to spool up any quicker than previously?
                          Hard to tell definitely, I can't see that the gas flow rate at low revs/low heat would increase dramatically by enlarging the dump pipe bore, as it would at higher revs/higher heat. I think the manufacturers of these custom pipes sometimes push that line purely for sales.
                          But I'm open to be corrected

                          Regards

                          Adrian
                          Silver '04 KZJ120~Manual~GXL~Dobinson/Kings lift~Custom valved Ironmans~Detroit Locker~Endless Air~X9 Superwinch~Madman EMS1~TJM Dual Battery~Rhino Roof Tray~120W solar panel~Foxwing awning~Bushskinz UVP~Long Ranger water tank~Bushman fridge~Steinbauer P-Box~Beaudesert 2 3/4"~Airtec Snorkel~TJM Sliders~Prico Boost Gauge~BFG-KO2s~TPMS~GME TX3420~Front and Rear Cameras~Ultimate Camper hanging off the back!

                          Comment


                          • #14
                            Re: Custom Dump Pipe 1KZ-TE

                            Mate, let me know if you make another one and I will fly up from Woy Woy, pay you and go and fit it. I'm keen for one. :wink:

                            Mark.
                            '06 120 GXL TD ARB bar, IPF Spotties, UHF, D694's... More to come

                            Comment


                            • #15
                              Re: Custom Dump Pipe 1KZ-TE

                              Well done Adrian.

                              You're a braver man than I... It's amazing what can be done in the confines of your own shed... :P

                              Mitch
                              [img]http://i49.photobucket.com/albums/f296/1cut808/MUMSRIG/Mitch-Prado.jpg[/img]

                              Comment

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