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Posted by: Aaron Cox Nov 11 2006, 09:39 PM

Ok, so i have a eurorace header. 4-1 hits a "turbo" muffler behind the trans and exits out the stock location...

what i would like to do, is make a Sport/GT muffler with the 2 tips and maybe even have the stock third outlet out the stock location... but retain the "bannana" shape

want the look and a gnarly sound, but can i make it work and look ok with a header system?

so i guess i would need a stock 4 or 6 or 911 bannana to gut.. and then weld up the inputs and weld a single 2.5" inlet from the collector?


your thoughts?

would look cool, may offer a bit of performance (uncork the sport pipes/cap em on the street), and hopefully sound cool.

Opinions welcomed.


-This look-

with this style /4 header system

Posted by: Twystd1 Nov 11 2006, 10:03 PM

Yes

Posted by: sixnotfour Nov 11 2006, 10:07 PM

use a sc , carrera muffler single inlet /outlet, Flip it so the inlet/outlet is on the right (for your header) Do the uppfixxin sport mod .....done.

Posted by: Aaron Cox Nov 11 2006, 10:38 PM

fountit - unfortunately the SC/Carrerra mufflers are waaaay different.

Posted by: VegasRacer Nov 12 2006, 06:45 AM

QUOTE(Aaron Cox @ Nov 11 2006, 07:39 PM)

Posted by: JPB Nov 12 2006, 08:33 AM

Sorry for the post deletion since it was not what you asked for and would have put me in a "Post Hijacking Hoe" catagory. Assuming noone has labeled me that yet

Just to be ahead of the bitchers and complainers.

I like the exhaust idea

Posted by: i love porsche Nov 12 2006, 09:10 AM

crazy..i want to do the exact same thing with my car....post pictures of how you do everything please

Posted by: mikez Nov 12 2006, 09:53 AM

Why bother?

Just unbolt it and attach a Supertrapp on the end.....looks like a big schlong....when the Betty's inquire, you simply say....mine's the same size.....

Then they'll ask....do ya have Mike's phone number?????

Posted by: Aaron Cox Dec 8 2006, 06:50 PM

ok- winter break is here... project time...
this is easily doable.....

so i got a FREE + shipping deal on an SC muffler....
here is the lovely peach ....err.... surgery victim




i found a thread on gutting SC/Carerra Mufflers on Pelican.

this is what they do...

open it up. remove center bulkead and baffles....


and here is a view from each end...



the gutted center section

Posted by: Aaron Cox Dec 8 2006, 06:52 PM

then all i gotta do is make the 2 center exits... and im inbusiness....


should start on it this week... tempted to go cut it open right now

Posted by: xitspd Dec 8 2006, 06:58 PM

MK muffler will build you anything you want in stainless. I am having a GT type (Dual Outlet) build for my car as we speak. Contact Dave B. at TRE Motorsports. I will email you pics when I get the car back.

Take care,

Dan

Posted by: Aaron Cox Dec 8 2006, 07:01 PM

that takes all the fun out if it dan!

just bored without a project - and this seems like a no brainer..

how you been man?

AA

Posted by: i love porsche Dec 8 2006, 08:11 PM

good thread...im going to have to bookmark this for further use...what are you going to do about the outlet pipes?

i think that megaphone outlets would look sick...

Posted by: Aaron Cox Dec 8 2006, 08:17 PM

i was gonna do twin 2" pipe.... about 6" or so long....

ive seen the megaphone idea done before.... not sure its my thing

Posted by: So.Cal.914 Dec 8 2006, 09:32 PM

Aaron will that not be as loud as LAX,,, not that I mind.

Posted by: Aaron Cox Dec 10 2006, 06:22 PM

PROGRESS!

so today the bannaner went under the knife...

my internals were a bit different then the pelican article seen here-
http://forums.pelicanparts.com/showthread.php?s=&threadid=181627

my nanner is from an SC and is about the same as a carerra...

so i opened it up.... what a PITA the spotwelds were (6 of em) about 5/8" diameter...
pilot hole kept wandering.... so i had to use a 1" hole saw.... (get to weld up those holes later....)

bgean cutting.
you can see the big ol holes to drill out the bulkhead spotwelds....

so the top was open now take out the innards....



went thru 4 cutting discs, 3 sawzall blades and some hammer and chisel work to remove it all.... took a few hrs..... wish i had a torch...

a view into each side....




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Posted by: Aaron Cox Dec 10 2006, 06:27 PM

just a remock up to make sure the shape hasnt changed....



now in this pic.. you can see where the outlet of the header is on the opposite side of the car...the inlet will have to be relocated...


chop chop the inlet. will be capped.... and relocated....



i will post a schematic of how i plan to mount/hang it off the trans, and where the inlet will be plumbed...

Posted by: Moron Sean Dec 10 2006, 06:33 PM

lookin' cool Aaaaaaaaaaaaaron.

Posted by: mikez Dec 10 2006, 07:36 PM

Nothing a SUPER Sawzall couldn't have fixed in a minute or two......

Posted by: Dan (Almaden Valley) Dec 10 2006, 07:50 PM

how does the weight compare?

by getting rid of a full bodied turbo muffler and the pipes, I would think it might be a bit lighter.

I will be interested in seeing how this turns out. I might try one myself...

I have a super light muffler for tracks where sound is not a problem...


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Posted by: nebreitling Dec 10 2006, 07:55 PM

i like that, dan -- you ought to weld it up.

Posted by: Dan (Almaden Valley) Dec 10 2006, 08:03 PM

QUOTE(nebreitling @ Dec 10 2006, 05:55 PM)

Posted by: xitspd Dec 10 2006, 08:04 PM

Aaron,

I love your projects, "they make me feel young again." I am doing fine. Do you remember the the car attached from the Ventura show?

Dan


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Posted by: Aaron Cox Dec 10 2006, 08:10 PM

hey dan -

glad to hear you are doing fine! thanks for the compliments....

that car was stunning!!! a beast like yours!!!

Posted by: Heeltoe914 Dec 10 2006, 08:13 PM

Aaron looks great hope you get the SOUND you wont. FYI your local If you ever need to cut like that again Come up and use my Plasma cutter and welders. Same for any 914 owner in So cal.
I love the sound of mine.


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Posted by: Aaron Cox Dec 10 2006, 08:15 PM

right on! if i am ever in the area, i will hit you up. (leamon right?)

BTW - how much por 20 to paint this bad boy when im done?

Posted by: Twystd1 Dec 10 2006, 08:16 PM

AA,

I am loving this thread.....

I believe the Jakester tested sumpin like this and gave it high marks.

Oh..... And dan..... Sorry about the drool marks on your windsheild at Ventura......
It just happens..... When I see your ride......

You just happen to own my dream car...............

Clayton

Posted by: Heeltoe914 Dec 10 2006, 08:19 PM

QUOTE(Aaron Cox @ Dec 10 2006, 06:15 PM)

Posted by: Eric_Shea Dec 10 2006, 08:20 PM

Looking good bud.

Excellent idea.

Posted by: Aaron Cox Dec 10 2006, 08:23 PM

BTW - anyone have flange dimensions for the euro race? i dont recall the dimensions and i have to have a flange made up (i remember i got the gaskets at the v8 shop)

BTW2 - how much por 20 do i need to paint this thing?

Posted by: Dan (Almaden Valley) Dec 10 2006, 08:33 PM

QUOTE(Aaron Cox @ Dec 10 2006, 06:23 PM)

Posted by: Aaron Cox Dec 10 2006, 09:16 PM

thanks dan!

Posted by: Dan (Almaden Valley) Dec 10 2006, 09:53 PM

QUOTE(Aaron Cox @ Dec 10 2006, 07:16 PM)

Posted by: Aaron Cox Dec 21 2006, 06:57 PM

woohoo.. more progress.

2.25" OD J bend (4" radius) from Jegs.com came today, along with a section of 2.25" OD straight tubing.....
got a flange from the muffler shop (2.5" ID )

ready to weld!!!

here is the plan!


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Posted by: Eric_Shea Dec 21 2006, 08:00 PM

Paint's on the way Biatch

Merry Christmas

Posted by: Aaron Cox Dec 24 2006, 12:08 AM

woohoo!

cant wait to weld this bitch up... and paint it with POR 20...

eric

Posted by: grasshopper Dec 24 2006, 12:11 AM

Now Eric...dont tell me you get it from Aaron too! Gahh....

Posted by: Eric_Shea Dec 24 2006, 01:24 AM

Dude... what don't you get about

Me=Stud

Posted by: Aaron Cox Dec 28 2006, 08:49 PM

but wait! there is more! LOL

spent all afternoon with craig downs trying to weld this bad boy up...

HUGE thanks to craig for all the help today (and tomorrow)

we got most of it done today.... another 2 holes/2 pipes to do... and weld the top on....

starting to make the input hole from the collector

Posted by: Aaron Cox Dec 28 2006, 08:51 PM

finished hole...


with the mandrel bend...

Posted by: Aaron Cox Dec 28 2006, 08:53 PM

craig spent most of the day welding in patches for the drilled out spotwelds...

metal was real thin.. and proved to be a PITA!
he had to go from mig to gas welding.


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Posted by: Aaron Cox Dec 28 2006, 08:54 PM

before finishwelding the input pipe...


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Posted by: Aaron Cox Dec 28 2006, 08:55 PM

grinders are your friend!

my feeble attempt at welding up the original inlet hole.

pre-grinding.


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Posted by: Crazyhippy Dec 28 2006, 10:42 PM

Now that's talent... i've never seen a dog shit in a circle... did you teach him that yourself?

Just ribbing the welds. Progress looks good

BJH

Posted by: Aaron Cox Dec 29 2006, 05:43 PM

BJ - laptop cleanup bill heading your way.. (snot removal from laughing so hard!)

more progress!

taking shape!


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Posted by: Aaron Cox Dec 29 2006, 05:44 PM

more!


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Posted by: Aaron Cox Dec 29 2006, 05:45 PM

craig is da man! spent another hlaf day with me on this.
we got all but the connection pipe between the collector and the new muffler done, and we made up a mount for the tranny....

we had his miller on the lowest setting and kept having hole issues... craig suggested we let his friend tig it up

thanks again craig!


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Posted by: Aaron Cox Dec 29 2006, 05:46 PM

last one for today!


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Posted by: Eric_Shea Dec 29 2006, 05:48 PM

Posted by: seanery Dec 29 2006, 05:48 PM

your neighbors are gonna hate you!

Posted by: Aaron Cox Dec 29 2006, 05:50 PM

QUOTE(Eric_Shea @ Dec 29 2006, 03:48 PM)

QUOTE

we had his miller on the lowest setting and kept having hole issues

That's weird. I read that in a post earlier as well... thin? My 911 muffler was something like 4-6 ply stainless. We just buzzed away at it with the MIG. No issues.

Posted by: Aaron Cox Dec 29 2006, 06:04 PM

QUOTE(seanery @ Dec 29 2006, 03:48 PM)

your neighbors are gonna hate you!

Posted by: tracks914 Dec 29 2006, 07:52 PM

I did something similar 2 winter ago for my 1.7. I took a spare muffler. cut it in half, drilled out the baffles and separators to give it a throatier sound, then welded a SS shroud and oval tip onto it.


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Posted by: tracks914 Dec 29 2006, 07:52 PM

Drilled...


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Posted by: tracks914 Dec 29 2006, 07:54 PM

Stainless Steel...


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Posted by: tracks914 Dec 29 2006, 07:56 PM

Side view..


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Posted by: tracks914 Dec 29 2006, 08:02 PM

and installed when I can find the picture...

Posted by: alpha434 Dec 29 2006, 08:15 PM

Dude. Cool.

Posted by: Crazyhippy Dec 29 2006, 09:16 PM

Have caps for the center pipes? And after all that work, why didn't you clean up the original tip too??

All this exhaust talk makes me want to re-do mine, think 3" is enough??

Posted by: Aaron Cox Dec 30 2006, 12:08 AM

i havent made the caps yet...

i have a brand new tip for the stock outlet

the thing is gonna get sanded/painted/por20'd after craigs friend gets done welding it

Posted by: Lou W Dec 30 2006, 02:08 AM

Looking good.

Posted by: Eric_Shea Dec 30 2006, 11:03 AM

Posted by: craig downs Dec 30 2006, 07:53 PM

Posted by: Aaron Cox Dec 31 2006, 12:25 AM

QUOTE(craig downs @ Dec 30 2006, 05:53 PM)

Posted by: Aaron Cox Jan 7 2007, 06:48 PM

quick update -

craig brazed the whole can up.... and we hit it with some metal etch/prep stuff..... threw it on the car for a mockup... mount holes need to be slotted a little more to center it perfect... but its lookin good....

soon it will be painted with POR 20 "manifold grey" paint....

now to start working on the caps for the sport pipes...




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Posted by: Crazyhippy Jan 7 2007, 06:57 PM

But how does it sound??

Looks good.

BJH

Posted by: Aaron Cox Jan 7 2007, 07:08 PM

in my last pic.. you can see the open collector...
a connection pipe has to be bent up or fabbed (still have a mandrel bend...) to connect the muffler to the collector...

it is basically an S shaped pipe.... needs to gain 2" of elevation and a bend to the right about an inch....

Posted by: swood Jan 7 2007, 09:12 PM

That looks great! Guud job.

Posted by: Crazyhippy Jan 7 2007, 09:27 PM

QUOTE(Aaron Cox @ Jan 7 2007, 05:08 PM)

Posted by: KaptKaos Jan 7 2007, 09:27 PM

Nifty!

Nicely done.

Posted by: Eric_Shea Jan 7 2007, 10:36 PM

It's 2007

Posted by: Aaron Cox Jan 7 2007, 10:39 PM

QUOTE(Eric_Shea @ Jan 7 2007, 08:36 PM)

It's 2007

Posted by: cnavarro Jan 8 2007, 09:03 AM

Excellent thread. Now if someone made a muffler like that you could buy to replace the stock muffler...

Posted by: Aaron Cox Jan 8 2007, 10:06 AM

and this is noticably lihghter than the stock eurorace street exhaust setup;

Posted by: Aaron Cox Jan 8 2007, 04:52 PM

so i think friday i will have time to get that connection/transition piece made up....

so moving along... the sport pipe caps.

My goal is to use these from mcmaster carr....


Fits Pipe Inside
OD Size Ht. ga. (Thick.)
2 3/8" 2" 1 1/32" 24 (0.0250")

with a 2 3/8 cap on a 2.25" OD pipe.. it gives it an 1/8" difference... or 1/16" all around...

my goal is to either drill 3 holes (every 120 deg) and tap them.. and use small allen socket set screws...
i have a feeling that the 24 gauge metal wont support that so i will have to weld on nuts over the holes... to give the set screws something to screw into... fill the inside edge of the cap with Orange hi-temp rtv to make a gasket.....

thoughts?

Posted by: Crazyhippy Jan 8 2007, 05:12 PM

cross pin like a trailer hitch ball? (smaller of course)

The problem w/ set screws is they might not be enough, and losing one in Barstow on the drive to RRC would suck.

BJH

Posted by: Aaron Cox Jan 8 2007, 05:23 PM

not gonna drill holes to pin them in LOL.....

and i really dont want to put anything for them to clasp onto either....

how are these held on? looks like a bolt


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Posted by: Crazyhippy Jan 8 2007, 05:29 PM

Looks like bolts....

Damn i'm good

Have to worry about vibration too, every exhaust pulse will cause the plugs to pulse...

Posted by: ChrisNPDrider Jan 8 2007, 07:23 PM

This is an awesome project!

Maybe the caps could be threaded on? That would look super clean...lots of anti-seize and maybe some small grooves or holes for a "tool" to unscrew them... I dunno. Those bolts don't look very cool to me. Good luck

Posted by: Aaron Cox Jan 8 2007, 10:03 PM

the pipe is only like 16 gauge... and threaded would look kinda fire-hydrant ish to me.....

i agree on the bolts... they dont look all that cool.....

any more ideas?

Posted by: jd74914 Jan 8 2007, 10:19 PM

Instead of drilling thru the pipe walls use a dull bit and bump in indents the size of set screw tips, then weld the nuts on the outside of the caps like you plan on. That way there is a little something for the set screws to "bite into" without putting then through the pipes.

I hope that made sense.

Posted by: Crazyhippy Jan 8 2007, 11:04 PM

tool box latches?? a hook on the pipe, and the latch mechanism on the cap??

Velcro?
Duct Tape?

BJH

Posted by: Aaron Cox Jan 8 2007, 11:30 PM

QUOTE(jd74914 @ Jan 8 2007, 08:19 PM)

Posted by: Twystd1 Jan 9 2007, 12:05 AM

AA...

Did ya ever wonder how those cheap computer desks at IKEA have telescoping legs?????

That is your answer. Totally hidden. Unsrews. Get's tighter with heat.

And we can make em..... With a little help from SpunOne... (Paul)

Think about it....

Thats your brain teaser for tonight.

C

Posted by: Aaron Cox Jan 9 2007, 12:10 AM

QUOTE(Twystd1 @ Jan 8 2007, 10:05 PM)

Posted by: jd74914 Jan 9 2007, 08:46 PM

QUOTE(Aaron Cox @ Jan 9 2007, 12:30 AM)

QUOTE(jd74914 @ Jan 8 2007, 08:19 PM)

Instead of drilling thru the pipe walls use a dull bit and bump in indents the size of set screw tips, then weld the nuts on the outside of the caps like you plan on. That way there is a little something for the set screws to "bite into" without putting then through the pipes.

I hope that made sense.

thought about that too...

the material isnt all that thick.......

what about something that expands from the inside??? stick it IN the tube and tighten....

Posted by: Aaron Cox Jan 13 2007, 06:20 PM

ok... so i went night boarding last night.... at mt high... froze my nuts off...

woke up early this AM.... pulled the muffler... finished the mount... centered it... all is well...

hooked up the DLEE tow setup... and drove down to meet up with clayton (twystd1) and jimmy... we then rocked out to jimmy's favorite exhaust fab place....

30 bucks later... and its all hooked up with a nice flange and copper collector gasket.. the guy did some bitchin welding...

so we played around with what 1 pipe vs 2 pipes vs 3 pipes sounds like....

DUDE... all i can say is WOW. it rocks.

nice and throaty at idle... and down low... really throaty thru the RPM range... and sounds great. then when cruising (think freeway speeds) it is Q U I E T! i can have a conversation in the car again LOL!!!

i plan on pulling it off and painting it with POR 20 soon.
thanks to clayton, jimmy, and most of all craig downs.

ill upload some pics and maybe a video later.

AA

Posted by: So.Cal.914 Jan 13 2007, 06:44 PM

Aaron I don't know if you figured out a way to plug those sport pipes but I

have an idea for you. Go to your FLAPS and ask to see quick replace freeze plugs.

They come in many sizes, you just put them in the hole and tighten the nut in the

center of it. A rubber is squashed and presses outward and seals the hole. It

withstands HOT water under preasure. You could replace the rubber with hi-temp

silicone rubber (not silicone in the tube), I used the silicone rubber for exhaust

connections on my nitro benzene out rigger hydro's (Hot) , lasted very well and

no holes.

Posted by: Aaron Cox Jan 13 2007, 06:46 PM

clayton and i devised a sinsister way to make sick caps... that remove with ease....

whenever we get around to making em that is LOL

paul - good suggestion! will make a great plan B

Posted by: Twystd1 Jan 13 2007, 07:22 PM

Yup,

AArons wacky exhaust sounds very nice...

But that ain't THE GOOD PART.........

The twin exhaust simply looks elegant and kinda tough at the same time.

I have see this setup before. And never ceases to amaze me how good they look.

I don't know how they perform from a dyno perspective. That is unknown.

But I wil tell you one thing... it improved a tuning stumble AA always had down low... In part transition.... (I mean his car... Not him)

Cause that problem is gone now.... Who woulda thunk the muffler woulda fixed this constant source of pissing me off.

Thats a win win in anybodys book....

CRAP.... Now I have to go make one for me......

Cudos to Craig Downs and AA for a job well done.

And Jimmy... Thanks for the hookup.

C

Posted by: Eric_Shea Jan 14 2007, 12:36 PM

You mean he finally finished it??

Posted by: Aaron Cox Jan 14 2007, 02:23 PM

just took it for a drive... and did some video... but my mic on the camera sucks balls....

pics before its painted....


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Posted by: Aaron Cox Jan 14 2007, 03:09 PM

my digi cam sucks at video......

http://www.youtube.com/watch?v=Q_GxinepsHk
http://www.youtube.com/watch?v=rKRZUW59vNk
http://www.youtube.com/watch?v=h7Luqqa_sn8

Posted by: So.Cal.914 Jan 14 2007, 03:28 PM

Very well done Aaron, can you get a pic of how you hung it on the car?

Posted by: thesey914 Jan 14 2007, 04:04 PM

Thats looks really really good. Looks like you have a six in there

Posted by: seanery Jan 15 2007, 09:29 AM

I smell a CLASSIC!

congrats to you Aaron!

Posted by: Aaron Cox Jan 15 2007, 03:36 PM

QUOTE(So.Cal.914 @ Jan 14 2007, 01:28 PM)