Anybody know where I can get an inexpensive new exhaust system for a '94 Yukon 6.5TD? I already called my favorite place, Pinnacle Exhaust, but they cannot make the full exhaust for a Yukon. Apparently the bends are too aggressive for their machinery.

Guess it depends on what you define as inexpensive. Even though the Tahoe/Yukons are a bear due to their short wheelbase, I have heard of folks piecing together pre-bent stock pieces and straight pipe purchased at truck exhaust shops with some success. My time has value and I decided to get JK's system. This was over 4 yrs ago and if I recall it was about $350, shipped to my door, installed in a few hours with no running around all over town. It can be done, just be sure to factor in your time and the quality of the end result when you make your "value" judgement. Good luck.

Anybody know where I can get an inexpensive new exhaust system for a '94 Yukon 6.5TD? I already called my favorite place, Pinnacle Exhaust, but they cannot make the full exhaust for a Yukon. Apparently the bends are too aggressive for their machinery.
I ordered the crossover and downpipe from summit for about 100.00 plus shipping. I installed it in bout 2 hours, including beer breaks, then had a local muffler shop remove the cat and muffler and run 3" out the back as I watched. I don't recall any major bends but Yukons floorpan is built differently somewhat. Anyway thats how I got where I am today with my exhaust.

i did what bowtie did. 3" custom bent all the way out. i had them install my pyro probe in the downpipe at the same time. the custom bending cost me $200 installed. i could have gotten him to do it with stainless for $100 more but i just went for the aluminized steel standard stuff he uses. it sounds amazing half the time i listen to that instead of the radio. i really love the decelleration vibrado whistle through the pipe.

Anybody know where I can get an inexpensive new exhaust system for a '94 Yukon 6.5TD? I already called my favorite place, Pinnacle Exhaust, but they cannot make the full exhaust for a Yukon. Apparently the bends are too aggressive for their machinery.
Too aggressive? Your talking about a 2dr right? Same as my Blazer, I had a custom bent 3" aluminized exhaust / hi-flow muffler / 4" tip put on mine for $300 Canadian Dollars, so whats that, like 50 bucks US? ;) They did a beautiful job too, all the bends are mandrel bent, and smooth, I can't imagine why they would have trouble with it.

A custom bent 3" has very little value over the OE 2.75" pipe...

when you leave out the muff, kitty, and factory downpipe it does.

Not by a longshot. Been on the dyno before and after. Gutted cat, no muffler vs KD exhaust:

did the gutted cat system have the stock downpipe? also i would think that a one piece 3" pipe would flow better than a gutted cat.

when i had my 97 tahoe 6.5td, i made my own 4" pipes using prebent exhaust elbows from my local truck shop... it was 4" muff less from the DP back... i never did end up taking pictures of the exhaust when i had it, and this (http://community.webshots.com/photo/33522556/33523228ghOEdj) is the only pic i can find with any exhaust visiable

If you guys like 3" performance you will love 3.5" really lowers EGT and gets the gasses flowing, need to lay 3" by a 3.5" tube to realize the difference, not much gain seen 3.5 to 4" several articles over at TDP site when I 1st joined there led me to 3.5 as the better choice. I bought Banks at the time as I was not aware of other vendors then, look around predominance of aftermarket pipe is 3.5", with 3" tubro down pipe, little room to stuff a big pipe in those confines.

dumb question time - has anyone ever taken off the exhuast after the down pipe and gone for a drive? Im just wondering how loud it was and what it sounded like. (No I have no intention of doing this just yet....hehehehe)

my exhaust comes out just past the cab on my truck. it is plenty loud from there. sometimes gives a headache at highway speeds.

A custom bent 3" has very little value over the OE 2.75" pipe...
True enough, its not a huge difference in size, smoother with mandrel bends and no cat either...the big difference is that it didn't have a stock exhaust when I bought it, it was a dual 1 3/4" setup that made very heavy and coarse bends and flowed through a singe 2" glass packed muffler...noisy and restricted.

dumb question time - has anyone ever taken off the exhuast after the down pipe and gone for a drive? Im just wondering how loud it was and what it sounded like. (No I have no intention of doing this just yet....hehehehe)Much bassier. a deep rumblling vibration, ):h hey all you need is an elbow and you could vent it behind the front tire. (joke)

And as for the difference in a CC K3500 2.75" and 3" straigt pipe the differece is night and day, JK. I'll get a bigger pipe one of these days, like when I cut the mount off the exhaust for the GM turbo and weld on a mount for the PS garret style. Then I'd want 3.5" or bigger from the downpipe back.