Upgrading to Bull Horn Stacks: A Guide to Customizing Your Big Rig

Upgrading to Bull Horn Stacks on a Big Rig

Adding a set of shiny new bull horn stacks to your big rig is one of the best ways to give it a custom, eye-catching look. Stacks are the large, vertical exhaust pipes that rise up above the cabin of the truck. Opting for a set of bull horn-shaped stacks rather than normal straight stacks gives your truck a more aggressive and bold appearance.

Bull horn stacks got their name from their unique curved shape that resembles bull horns. The gentle bend and flare at the top helps improve exhaust flow while also providing a rugged yet sleek look. Bull horn stacks are a popular choice for truckers looking to upgrade their rig's style.

Benefits of Bull Horn Stacks

There are several advantages to installing bull horn stacks on your semi truck:

• Improved exhaust flow - The curved shape improves and smoothens the airflow compared to straight stacks.
• Enhanced engine performance - Better exhaust flow leads to optimized engine performance.
• Distinctive style - Bull horn stacks provide a customized, eye-catching look that stands out on the road.
• Increased engine braking power - The vertical design increases exhaust scavenging for improved engine braking power.
• Louder exhaust note - The stacks redirect the exhaust noise upwards, leading to a more aggressive exhaust tone.
• Vintage appeal - Bull horn stacks are reminiscent of old school truck designs, evoking a retro flair.

So if you're looking to boost both the style and performance of your big rig, upgrading to bull horn stacks is a great option.

Choosing the Right Size Bull Horn Stacks

Bull horn stacks come in a range of sizes, usually ranging from 4 inches up to a giant 10 inches in diameter. The most common sizes are 4, 5, 6 and 8 inches. Here are some tips on selecting the right sized stacks for your truck:

• 4-inch stacks - Best for lighter duty trucks with smaller engines like straight trucks. Provides a balance of improved flow and noise without looking too ostentatious.
• 5-inch stacks - A nice middle ground size that works well with many Class 7-8 tractors. Big enough to make a statement but not overly huge.
• 6-inch stacks - Ideal for larger engines in the 15+ liter range. Provides increased exhaust flow capabilities for high-output motors.
• 8-inch stacks - One of the most popular choices for heavily modified trucks running high horsepower engines. Makes a bold styling statement.

Make sure to select a stack size that is appropriate for the size of your truck's engine and performance needs. You want stacks that can handle the exhaust flow while achieving the look you're going for.

Stack Styles and Designs

Beyond just the size, there are many different styles and aesthetic design options when selecting bull horn stacks, including:

• Tip shape - Choose from tapered, flared, or rolled tips.
• Material - Polished stainless steel and chromed steel are most common. You can also find powder coated or blacked-out finishes.
• Single or dual - Opt for a single stack on each side, or go big with duals.
• Angles - Some stacks feature multiple bends rather than a single curve.
• Length - Longer stacks extend further above the roofline for maximum visibility.

There are many stack configurations to give your truck exactly the look you have in mind. Just ensure your choices are street legal and don't excessively obstruct visibility.

Installation Tips

Once you've selected the perfect set of bull horn stacks, it's time for installation. Here are some tips for properly mounting your new stacks:

• Have an experienced shop install them unless you really know what you're doing. Proper exhaust system work is complex.
• Stacks mount to the top of the vertical exhaust pipe. Ensure this area is reinforced to support the weight.
• Seal all connections thoroughly to prevent harmful exhaust gases from leaking into the cabin.
• Aim the outlet of the stacks away from the trailer for improved dispersion of exhaust.
• Check ground clearance and make sure stacks clear any add-ons like air shields on the roof.
• Ensure exhaust wrap or insulation protects nearby wiring, hoses, etc. from heat damage.

Taking the time to properly install your new bull horn stacks will ensure they mount securely, exhaust well, and look exactly like you envisioned. It really makes a truck stand out from the crowd.

Maintenance and Performance of Bull Horn Stacks

Adding those awesome looking stacks to your truck isn't the end of the story. To keep them looking and performing their best for the long haul, some simple maintenance steps should be followed.

Keeping Stacks Looking Sharp

Because bull horn stacks sit high up and extend out from the truck, they can be prone to just looking grimy from road dirt and exhaust buildup. Here are some tips for keeping them gleaming:

• Hand clean the stacks at truck washes using quality chrome or stainless polish and microfiber cloths.
• For tough built-up exhaust soot, carefully use a metal brush and chrome cleaner to scrub stacks.
• Rinse well after cleaning and allow to fully dry before starting engine.
• Wax or seal stacks every few months to protect the finish from corrosion.
• Remove any loose fasteners or clamp connections and re-tighten to prevent rattling.

It's satisfying to show off a set of stacks you can see your face in, so take the time to keep them properly polished up.

Performance Maintenance Tips

To ensure your stacks continue to function well, check the following areas regularly:

• Check all clamps and support connections for any looseness from vibration. Re-tighten as needed.
• Inspect for any exhaust leaks at stack joints. Realign or reseal to prevent leakage.
• Make sure exhaust wrap or heat shields are intact, replacing any damaged sections.
• Look for any cracks in the stacks themselves. Small cracks can lead to bigger issues.
• Listen for unusual exhaust noises like rattling that could indicate an internal pipe issue.

Well-installed and maintained bull horn stacks should last for years and many miles of reliable service. But periodically checking for any wear or looseness helps avoid more serious problems down the road.

Legal Considerations of Bull Horn Stacks

Although most truck enthusiasts love the look of bull horn stacks, some states have regulations regarding their legality on tractor trailers using public roads. Here are some guidelines on stack legality:

Stack Size Rules

Some states restrict drivers from using overly large stack diameters. For example, in Florida the maximum legal diameter for exhaust stacks is 6 inches. Anything larger could result in a fine if caught by highway patrol.

Stack Height Regulations

Many states limit how high stacks are allowed to extend above the roof of the tractor. Common height limits range from 12 inches to 15 inches above the cabin. Excessive stack height can be a safety hazard leading to citations.

Smoke and Pollution

Most states prohibit any modifications that increase exhaust smoke opacity or pollution levels. So stacks cannot be installed without properly functioning mufflers and emissions controls. Removing things like catalytic converters is illegal.

Also, deliberately rolling coal by modifying the engine to blow excessive smoke can lead to fines in many regions.

Always Know Your Local Laws

The exact laws regarding bull horn stack legality, size, and height vary from state to state. Do thorough research before making any exhaust modifications to ensure your awesome new stacks don't lead to tickets and fines. Most well-installed stacks should be legal, but it's always smart to check your particular state's requirements.

With the proper legal stack setup installed, you can cruise around and show off your big rig's killer new look without hassle from the authorities. Bull horn stacks might not be for everyone, but for many truckers they are one of the best ways to customize your ride and stand out from the crowd! With the right stacks bolted on, everyone will be checking out your awesome rig rolling down the highway.

FAQs

What size bull horn stacks should I get?

The most common stack sizes range from 4-8 inches in diameter. Choose a size appropriate for your truck's engine and performance needs. 4-6 inches works well for most class 7-8 tractors. Larger stacks are better suited for heavily modified trucks with high horsepower engines.

How high can I legally mount my stacks?

Stack height laws vary by state, but usually limit extended height to 12-15 inches above the roof of the truck cab. Make sure to research regulations in your operating region before installing stacks that are too tall.

Will bull horn stacks improve my truck's performance?

Yes, properly installed stacks can provide increased exhaust flow and scavenging which improves engine efficiency. This leads to modest power gains along with stronger engine braking capability.

What material should I choose for my stacks?

Polished stainless steel and chromed steel are the most popular stack material options. Stainless has better corrosion resistance while chrome provides a brighter finish when clean. Power coated and blacked-out finishes are also available.

How can I keep my stacks looking clean?

Regularly hand polish them with quality chrome or metal polish and microfiber cloths. For stubborn soot buildup, carefully scrub with a metal brush. Always rinse and dry fully after cleaning. Apply wax or sealant every few months to protect the finish.