Henry put the final touches on the new exhaust system today and it looks and sounds great.
You can see the problem in previous posts but here’s one more photo of the exhaust manifold and the modified bolt/nut (yellow arrow) that was hammering the down pipe (red arrow).
I think the old exhaust pipe was and inch-and-a-half in diameter. The new pipe is three inches and no muffler. Sounds like a tractor-pull and feels like I have 10% performance boost. Hangs a little lower but I’m not planning any off-road adventures.
Part of the reason the exhaust was getting pounded was the left wheel stop wasn’t bent. George replaced and adjusted both wheels so the pipe is now protected.
George and his cohorts just keep making the truck better and better. Next enhancement: replacing oil bath air filter with one that will let my baby breathe!