The engine in my 85 300 TD was replaced in CA at 8k miles. Supposedly ,the trap ox malfunctioned and lunched the motor. They vehicle then moved to Ohio where at 305 k later , still has the cursed TO and subsequent air cleaner with John Deere filter element.

Question- via a rumor mill started by some guy named Gunter at the MB dealership in Carmel Ca, the TO then fitted was "empty" and "vould caus nmore problem"

The trans seems different than my ex 49 state TD(smaller) , and it's definitely slower. What are the chances that the TO is in fact "empty" and if a fit a test pipe, I wouldn't see a difference. Ohio has no echeck.

There is one consolation about this Kali crazyness is that the programs put in place did make a difference. For those who remember the days of Smoggy Los Angeles back prior to the 1990's, in which there was a constant haze going on. You couldn't see the mountains towards the north which were not too far away.

http://www.peachparts.com/shopforum/...1&d=1343066310


Today it is much cleaner. But still on occasion a few smog days.

http://www.peachparts.com/shopforum/...1&d=1343066682

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The problem with knocking the honey comb stuff out is your left with a big cavity that just collects exhaust and not directing the flow very well to the turbo. You'll experience more turbo lag then a narrow pipe.

The transmission is indeed different. It's a weaker then the Federal.

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I agree it could potentially be simpler, however, keep in mind I'm running a non-stock configuration - namely a 617.952 in a 107 chassis, not a 123 chassis and there may not be room due to the smaller engine bay. If true, I'd be pulling all the federal gear and attempting an install only to potentially find out it wouldn't fit and then have to go back and do a test pipe, which would end up being more work. Heck, just redoing my current down pipe would be about the same amount of work as doing the test pipe.

All that being said, if I find a nice federal setup at a decent price down the road, I'll pull it and give it a shot.

My "test" pipe
 

My test pipe was purchased over the Internet. I still have quite a few more tests to perform. I do still have my trap-oxidizer; it has cracked the concrete floor because of the weight.:rolleyes:

From a purely technical standpoint I wonder about the extra length from a KaliKar exhaust manifold exit which is at the back of the block. The exhaust gases then have to travel forward to the turbo--about 12 inches. Don't Federal cars have the exit point of the exhaust manifold directly next to the turbo, which gives them minimal tube length?

PS. My car's story must be good. I found the original owner papers. The original owners lived in Houston. They travelled to Kali, purchased the car and then drove it back. So they chose to buy the KaliKar model.

There was 2 sources that sold the test pipes already made for $250-$275. One was still around last year.

The good thing about swapping the Fedaral Parts to yours is if it ever does need inspection it wil look like it was manufactured that way. The Person doing Inspection might not have the Knowlege to know the difference.

Here is the finished test pipe.

http://www.peachparts.com/shopforum/...1&d=1343101768

I used a mandrel bent 180 degree 1-7/8" with a 3" radius for the main pipe. I just cut this in half and used one half for each 90 on the turbo inlet and exhaust outlet respectively.

The transition piece from the pipe to the turbo is made from a 2" two-into-one collector piece that was cut down to fit the flange of the turbo perfectly. I used the excess cut off piece of the two-into-one to make the sleeve to join the two 90 degree pieces.

The material cost was $31 plus welding wire and ceramic paint.

Don't look too closely at the welds - they're not pretty, but they're not going anywhere either. :)

I like how your version straightens exhaust flow for a direct shot at the turbine. Other versions send exhaust into the turbine at an angle. I don't know if it amounts to a difference but I prefer your finished product :)

Sixto
87 300D^2

You beat me to it! I have been so busy with my 617 Sanden compressor project, that I have not had time to build a fixture (politically correct term) for a test pipe. I have 2 broken TO's to use the flanges from. If you need a set, let me know. Or I may just send them to you and have you make them up for me since you already have a fixture....Rich

You're welcome to use the jig any time you would like. I'll bring it up for the next GTG. Thanks for the offer on the flanges, but I've got a spare, as well as the one that's in the car now that will be put back in once the testing is completed.

Installed the test pipe today and took her for a spin. WOW! what a difference. Of course a big part of that was probably getting rid of the 2 large pieces of disintegrated Trap Cat ceramic that was lodged in the turbine housing. Anyway, the car runs so smooth, spools up quickly, settles in at 9.5 pounds of boost almost right away and I can get just a hint of turbine whine. The power is noticeably better and I believe that it idles considerably smoother as well.

http://www.peachparts.com/shopforum/...1&d=1344132997

If anyone wants to buy my black test pipe or rent the jig, just let me know.

Now I'm ready to fill up the tank and do a closed circuit run to get an accurate highway mileage reading.