1-in/2-out Muffler input needs alteration, Any advice ? Options

[Literati914]

I have a set of 4 into 1 stainless headers that I want to connect up with an old stainless steel 1in-2out Tangerine muffler. The muffler was obviously not made for this header system but they are not that far off either. Well a little is a lot in this case I guess.

I have a MIG welder and thought I’d buy some self-shielded stainless wire (rather than invest in a whole tank of gas), and try to fix the gap. If nothing else I figured I could tack up a solution and let a real welder finish it (if blowing holes became unavoidable).

I’ve found that the tube exiting the muffler is apparently made up of mild steel at the flange (magnet sticks strongly), then the curved mid-section of the tube is a low carbon steel (magnet sticks BUT NOT strongly), then the very short part is all stainless as is the rest of the muffler (magnet does not stick).

I’m looking for suggestions as to where you guys would cut, maybe good only spots to buy pre-curved stainless or what to search for. General suggestions would be appreciated. Part of wanting to take on this task is that I’d like to add to my welding experience if I can. Here are some pics of the project:

[Literati914]

Right, your suggestions are along the lines of what I’ve been thinking.. only thing though is that I’m gonna need a “small drop down” section (probably just off the muffler) - like a soft “Z” shape, to get to the lower placement of the header flange. Is anything like that even available- or would it need to be made ?