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Posted by: Scott S Mar 12 2012, 04:41 PM

Hi All -
Per the attached pic, anyone have any ideas on how to recreate the baffle shown inside this GT tail pipe?

I guess I could make a few very small stand offs on the outside of some perferated pipe, then drill some holes and plug weld it from the outside of the tail pipe. Getting the lip clean will not be fun...

Any suggestions are greatly appreciated.

Posted by: SirAndy Mar 12 2012, 04:50 PM

Older Beetle tailpipes have a similar insert. Not sure of the diameter on those, but there are also aftermarket pipes for the beetle that are larger with the same style insert.

Useless trivia:
That oh so familiar high pitch "whining" sound you hear from a old beetle exhaust comes from those inserts!
They work themselves lose over time and start to rotate and vibrate in the pipes causing the whiny noise.

Posted by: McMark Mar 12 2012, 05:52 PM

I suspect that those are press fit installed.

Posted by: SirAndy Mar 12 2012, 06:12 PM

You are correct ... Which is part of the reason they come lose over time ...

Posted by: wingnut86 Mar 12 2012, 06:52 PM

$30 cheese grater from Kohls. Strip the stainless grate away from the frame and handle. Weld the 2 long ends together and tap sown an old wooden bat to straighten the piece and clean the bats surface;-)

Weld the end cap of an aluminum coke can to one end and drill out the excess center. Jam the baffle into the pipe, tack weld and go.

The shit we used to do in 70's seemed so cool, and almost as legal

Posted by: jmill Mar 12 2012, 07:19 PM

So in the 70's you could weld aluminum to stainless?

I did see some guy at the local wood show gas welding up holes in aluminum cans but even he had a different rod for steel.

Posted by: wingnut86 Mar 13 2012, 10:23 AM

In the 70's, the cans weren't aluminum

Posted by: 7TPorsh Mar 13 2012, 11:53 AM

Tailpipes on a Ford Flex look similar,

Posted by: r_towle Mar 13 2012, 01:07 PM

a small hole punch and alot of patience.

rich