Pipe Music
The diesel market is growing at a rapid clip, partly because consumers have discovered how much power can be gained with only a few simple modifications. A performance exhaust is one of the quickest and most cost-effective ways to improve a diesel's performance. No surprise, then, that this type of product is one the most popular aftermarket add-ons among owners of diesel trucks.
That enterprise expanded rapidly, so much so that Car Sound began producing catalytic converters for virtually every make and model of vehicle manufactured or imported into the United States since 1975. When the EPA passed emissions standards allowing aftermarket manufacturers to build and test catalytic converters for the replacement market in 1986, Car Sound immediately began developing and testing new catalysts.
As the company continued to grow, it produced catalytic converters that were — and still are — all designed, developed and manufactured to meet the strict and evolutionary emission control standards imposed by governmental agencies worldwide, including the EPA and California Air Resources Board. But as noted up front, diesel enthusiasts look at their exhaust systems for another reason: performance. Recognizing that fact, the company decided to develop a line of exhaust components that would provide more power.
So in 1995, Car Sound added the MagnaFlow Performance line, making performance mufflers and cat-back exhaust systems for cars, trucks and SUVs, beginning with a few tried-and-true vehicles such as the Ford Mustang and Chevy pickup. The lessons learned over the years in the development, production and distribution of catalytic converters were applied to the new line, which soon found a following in the diesel marketplace as well.
However, it's not a matter of simply increasing the size of a diesel exhaust pipe. Even if you still have sufficient backpressure to spin the turbo, how do you know if you've gone too far? Anything much above a 4-in. tube might not result in big power gains, and a cat can slow down the flow as well. Also, fitting a large tube can be a challenge.
The company addressed all of these concerns with its new 5-Inch Turbo-Back Exhaust System. The bends are much smoother than stock, simplifying installation. And the dyno numbers don't lie. The system makes significantly more power and torque than the factory unit.
On a Cummins-powered 2006 Dodge Ram 3500 Mega Cab, for example, we saw increases from a stock output of 214.6 to 228.1 hp at 3,000 rpm, an improvement of 13.5 horses. The results on the torque side were even better: a jump from 450.6 ft.-lbs. at 2,250 rpm to 475.4 ft.-lbs. That's a gain of 24.8 ft.-lbs., simply from changing the exhaust tubing and muffler.
MagnaFlow's Brian Van Dyke says that other testing on similar vehicles has indicated improvements of 11 hp and 35 ft.-lbs., which can vary depending on environmental factors such as temperature and time of day. (Note, however, that federal guidelines prevent manufacturers of aftermarket catalytic converters from making performance claims, because they're technically replacement parts, but the numbers speak for themselves.) The company offers a number of systems for the most popular diesel engines, including the Cummins, Duramax and Power Stroke. The company says its exhaust products can also lower exhaust gas temperatures and improve fuel economy.
All of the pipes are mandrel-bent stainless steel tubing for optimum flow. The 7-in.-diameter stainless-steel muffler is designed to provide just enough backpressure to keep the engine happy while not being a hindrance to exhaust flow. The system also includes a 6-inch diameter polished stainless-steel exhaust tip for cosmetic appeal, various types of high-quality clamps needed for installation and detailed instructions. The system comes with a lifetime warranty and is a functional and emissions-legal addition to today's high-performance diesel engines.
One thing we can't convey in a magazine article, though, is just how it sounds. If you'd like to actually hear a MagnaFlow exhaust, go to the company's Web site and listen to the pipe music.
Steve Temple is a freelance technical writer and photographer with more than 25 years' experience. He has served as director of sales and marketing for Shelby American and as online editor for major magazines such as Hot Rod, Car Craft and Rod & Custom.
