Heavy Metal Mudder Phase II Part 7: Wiring & Exhaust

Heavy Metal Mudder Phase Ii Wiring Exhaust 3 Inch Pipe

As the exhaust exits the V-10 headers, each bank merges into a 3-inch collector. Once the exhaust path is determined, a series of test fits and TIG welds begins and our custom dual exhaust system slowly starts to take shape.

As the exhaust exits the V-10 headers, each bank merges into a 3-inch collector. Once the

Over the past six months we've worked tirelessly to transform our '99 Dodge Durango into a machine fitting of its Heavy Metal Mudder name. With the Viper V-10 finally secured in place and the majority of the powertrain now complete, we turned our focus on some of the smaller yet extremely important items.

As we continue wrenching alongside the National Speed crew in Wilmington, North Carolina, we're extremely anxious to hear the 8.3L fire up and get this monster in the dirt. But before we can even think about turning the key we have to tackle the intricate wiring, plus plumb out the remainder of our exhaust system.

To keep the build moving expeditiously, the Speed crew teamed up with the metal magicians at Momentum Performance to finish out the work on our custom exhaust system. This allowed National Speed's GM Chris Polanski to collaborate with our East Coast Viper expert, Tom Sessions, to focus on the electrical system.

We understand that not everyone has a veteran Viper tech working down the street, but if you're considering such a swap, we suggest at the very least finding someone who has in-depth knowledge of the Mopar machines and access to the technical data.

Wiring is one of the most crucial and time consuming parts of any build, and it's important when performing a swap as complex as this to have the wiring diagrams of both vehicles in arm's reach. Interfacing the pieces from the donor vehicle and the project truck will take a little work, but it's defiantly not impossible. Just plan on spending some time under the hood. This is especially true when you are merging A/C controls and tach signals and have as many power accessories as we have.

Heavy Metal Mudder Phase Ii Wiring Exhaust Engine

Next Month
We are literally an issue away from firing up our Heavy Metal Mudder and tackling the terra. With most of the larger hurdles out of the way, the finish line is finally in sight! Be sure to check us out next month to see what final touches it takes to get this monster Durango ready to launch.

Though the belly of our Durango rests a couple feet off the ground, we didn't want to sacrifice any ground clearance with a low-hanging exhaust system. In order to keep the twin 3-inch pipes running parallel and tucked out of the way, we used a torch to massage the tubing form.
Though the belly of our Durango rests a couple feet off the ground, we didn't want to sacr
Oftentimes custom exhaust systems will require the O2 sensors to be relocated farther back. Do not cut and extend your factory O2 harnesses, as doing so would lead to more problems down the road. To make the system work properly we purchased a set of extension harness from Belanger Headers.
Oftentimes custom exhaust systems will require the O2 sensors to be relocated farther back
To give our 8.3L a smooth rumble, a Magnaflow muffler was installed that was specially developed for the SRT-10 Ram truck. Inside the muffler the exhaust crosses over, which eliminates much of the reverb commonly associated with high-performance dual exhaust systems.
To give our 8.3L a smooth rumble, a Magnaflow muffler was installed that was specially dev

The engine wiring harness we picked up from Arrow Racing Engines was pretty straightforward and easy to install. Unlike the older 8.0L Viper engines, the newer 8.3L fits the coil packs and electronics under the intake versus the back of the block.
The engine wiring harness we picked up from Arrow Racing Engines was pretty straightforwar
Our outside wiring help came from expert Viper tech Tom Sessions. Using his years of knowledge and online diagrams from Chrysler, we were able to merge the two vehicles one wire at a time. If you don't have online technical data access, try using a Chilton's or Haynes manual. They have been extremely helpful to us in the past.
Our outside wiring help came from expert Viper tech Tom Sessions. Using his years of knowl
The heart of the electronics is the '05 Dodge Ram SRT-10 J-Tec controller that was purchased directly from our local Dodge dealer. The J-Tec works as the power control module for both the 48RE automatic transmission and the 8.3L engine. We have ours piped into our original OBD-II code reader so we can monitor any issues or codes we may have. Obviously this isn't a factory SRT-10 configuration, so once we have the truck up and running we will send out the PCM to have it recalibrated.
The heart of the electronics is the '05 Dodge Ram SRT-10 J-Tec controller that was purchas

To provide juice to our new setup we installed an Optima RedTop battery. Red Tops are known for their quick charging and work great to keep up with the demand of our electric fan setup.
To provide juice to our new setup we installed an Optima RedTop battery. Red Tops are know
Helping the V-10 breathe easier and pick up a couple ponies is a K&N cold air intake designed for an '05 SRT-10 Ram. We were pleasantly surprised when we found the that washable filter and intake setup fit under the hood without any modification.
Helping the V-10 breathe easier and pick up a couple ponies is a K&N cold air intake desig
Since the custom doghouse sits roughly a foot past the original firewall, we had to be creative when fabricating a new home for our custom HVAC system. Momentum Performance massaged in a small yet powerful blower wheel and connected it to a series of custom tubing vents. The result is a heating and A/C system that works almost better than stock. We even managed to keep the rear A/C tied into the system so the back five passengers can stay cool too!
Since the custom doghouse sits roughly a foot past the original firewall, we had to be cre

With our custom Auto Meter gauge holder in place, we wired each of the eight gauges to its appropriate sending unit. ...
With our custom Auto Meter gauge holder in place, we wired each of the eight gauges to its
...Attaching our new gauge cluster in place, we started to fit the interior and dash back together.
...Attaching our new gauge cluster in place, we started to fit the interior and dash back
While we had to get a little inventive to support the original dash, it went back in place without any major issues. We even managed to reuse all the factory climate control knobs and radio, and all the lights still work!
While we had to get a little inventive to support the original dash, it went back in place

SOURCES
National Speed Inc. Wilmington NC www.nationalspeedinc.com	Momentum Performance Wilmington NC www.momentumperformance.com
K&N Filters 1455 Citrus Street Riverside CA 92507 800-858-3333 www.knfilters.com	Arrow Racing Engines N/A AK 248-852-5151 www.aarowracingengines.com
Tom Wood's Custom Driveshafts 2147 N. Rulon White Boulevard Suite #103 Ogden UT 84404 801-737-0757 www.4xshaft.com	Optima Batteries 17500 E. 22nd Ave. Aurora CO 80011 303-340-7400
Auto Meter 413 W. Elm Street Sycamore IL 60178 866-248-6356 www.autometer.com	Belanger Headers N/A AK 877-423-7878 www.belangerheaders.com
Mopar P.O. Box 21-8004 Auburn Hills MI 48321 800-992-1997 www.mopar.com	MagnaFlow Performance Exhaust 22961 Arroyo Vista Rancho Santa Margarita CA 92688 800-824-8664 www.magnaflow.com