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Creating A Complete Exhaust System: Do’s & Don’ts

Designing A Complete Exhaust System

At DBA Silencing, we make all sorts of parts. Coolant parts. Air intake parts. Exhaust parts. If we’re being honest, however, exhaust is our favourite. {Please don’t tell air intake and coolant; they’ll only be jealous.} This is largely because we started with exhaust, and exhaust continues to be our primary focus. As you can imagine, we’ve spent a lot of time over the decades amassing knowledge about exhaust components and exhaust systems.

With all this experience under our belts, we’re now able to put together a complete exhaust system for just about any application. Mining trucks. Logging vehicles. Fishing vessels. Even buildings that require specialized venting. In this article, we’re going to share with you our thoughts on what to do and – perhaps more importantly – what not to do when it comes to constructing exhaust systems.

Insulated Exhaust Pipes of complete exhaust system

Component Size & Mounting

As mentioned in previous posts, DBA is an OEM supplier for Liebherr Mining Equipment and an aftermarket supplier for all our other customers. {Customers such as Teck Coal, Imperial Oil, Caterpillar, Cummins, and Suncor.} In aftermarket situations, our exhaust system kits are replacements for the OEM {or Original Equipment Manufacturer} assemblies. In some cases, our complete exhaust kits are similar to their OEM equivalents, and there is an element of interchangeability. In other scenarios, we introduce improvements.


Our aftermarket parts often cost far less than their OEM counterparts; a mining exhaust system from DBA could easily offer a savings of 50%. This is one of the main reasons that companies transition to using DBA alternatives. One of the other reasons firms make the switch is that OEM exhaust components are in some instances enormous and unwieldy. These monoliths are so long and heavy that installing them often requires a crane, or at least a team of people. We dislike designs where a complete exhaust system kit is composed of a smaller number of weighty and massive components.


At DBA Silencing, we have a different approach. We divide our exhaust arrays into a larger number of lighter individual parts. A kit exhaust system broken up in this way has a number of advantages. First: initial installation is much easier. Second: it’s cheaper and simpler to replace a part that’s been damaged. Third: it’s possible, when your system is separated, to mount it in such a way that it flexes with the movement of the truck. Exhaust pipes that are locked into a rigid and unyielding framework will often crack in the field. We like to think that, for these reasons {as well as the ones outlined below}, DBA exhaust kits are the best exhaust kits.

Heat Management

Exhaust system kits are challenged not only by bouncing and vibration, but also by exceedingly high temperatures. Parts coming off the turbocharger, in particular, are subjected to serious amounts of heat.


It’s important, when you’re designing a mining exhaust system, to ensure that the surface temperature of the various components remains below the flash point for operating fluids. This is because, if parts get too hot, even minor malfunctions such as oil leaks can result in major problems such as truck fires. Some manufacturers combat heat by constructing complete exhaust kits that feature double-walled tubing.

Although a double wall can successfully reduce surface temperatures, it adds a lot of pounds. And extra weight, as detailed above, can cause issues by adding to the stress on the kit exhaust system. Insulating blankets are another solution often found in the field. In our experience, however, people assigned to installing blankets absolutely loathe them. This is because, according to many of our customers, they are a pain in the neck to properly fit and attach.


If you have a complete exhaust system kit from DBA, you have parts encased in heat-resistant fibreglass shells. Our proprietary insulating shells are unique in the industry, and they are so effective that – even when a truck is running – an operator can place an unprotected hand on an exhaust part and then pull it back without a burn. You can see a video of this happening on the home page of our website: dbasilencing.ca.

Noise Reduction

It’s impossible to entirely eliminate the sound produced by a vehicle as gigantic as a mining truck. That said, some designs are better than others when it comes to reducing racket.

Mufflers as part of complete exhaust system


At DBA Silencing, we fashion our exhaust parts from high-quality aluminized steel tubing. Our most common diameters are 8”, 10”, and 12”. Some manufacturers, when putting together a complete exhaust system, will vary the pipe size. And sometimes it is indeed necessary to transition – within a system – from one diameter to another. We offer reducers and adaptors in the Exhaust Accessories section of our website. Generally speaking, however, it’s best to keep the pipe size uniform throughout the kit exhaust system. This is because increasing the diameter can, under certain circumstances, turn your exhaust array into a sort of megaphone. Which is, of course, the exact opposite of what we want!


If you’ve designed a complete exhaust system kit and it’s running a little loud, you can always consider adding a resonator at the tail end of the assembly to dampen things down a bit. You can also look into modifying the gut configuration of your muffler{s}, so as to break up the sound waves more effectively. You have to be careful with this process, as changes to gut design will alter the operation of the venturi effect, and can potentially increase back pressure on the engine. Of course, some engines actually run better with slightly more back pressure, so experimentation and fine tuning is often needed.

A Complete Exhaust System From DBA

As mentioned above, we believe that DBA exhaust kits are the world’s very best exhaust kits. If you’d like to chat with us about why we think this is the case, you’re welcome to dial our digits: 1-800-661-5886. If you’re closer to our headquarters in Port Alberni, British Columbia, you can use our local line: (250) 723-2288. And if you’d prefer to just scroll through our current catalogue, you can find a copy on our website.

In closing: DON’T hesitate to reach out to us for all your exhaust system needs, DO feel free to contact us anytime!

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