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> Making a Sport muffler for a /4 Header, using a 911SC Muffler. Project "tri-tip"
Aaron Cox
post Dec 28 2006, 08:53 PM
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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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Aaron Cox
post Dec 28 2006, 08:54 PM
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before finishwelding the input pipe...


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Aaron Cox
post Dec 28 2006, 08:55 PM
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grinders are your friend!

my feeble attempt at welding up the original inlet hole.

pre-grinding.


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Crazyhippy
post Dec 28 2006, 10:42 PM
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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
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Aaron Cox
post Dec 29 2006, 05:43 PM
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BJ - laptop cleanup bill heading your way.. (snot removal from laughing so hard!)

more progress!

taking shape!


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Aaron Cox
post Dec 29 2006, 05:44 PM
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more!


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Aaron Cox
post Dec 29 2006, 05:45 PM
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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 (IMG:style_emoticons/default/smile.gif)

thanks again craig!


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Aaron Cox
post Dec 29 2006, 05:46 PM
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last one for today!


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Eric_Shea
post Dec 29 2006, 05:48 PM
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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. (IMG:style_emoticons/default/confused24.gif)
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seanery
post Dec 29 2006, 05:48 PM
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your neighbors are gonna hate you! (IMG:style_emoticons/default/laugh.gif) (IMG:style_emoticons/default/Jumpy.gif) (IMG:style_emoticons/default/w00t2.gif) (IMG:style_emoticons/default/w00t1.gif)
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Aaron Cox
post Dec 29 2006, 05:50 PM
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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. (IMG:style_emoticons/default/confused24.gif)


this is a later bischoff SC muffler...
it WAS 2 layers of mild steel... but when you gut it... the inner layer goes the way of the dinosaurs....

so just 1 layer on the top of the can.....

BTW - cute little thing of POR 20 came today. Thanks eric.
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Aaron Cox
post Dec 29 2006, 06:04 PM
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QUOTE(seanery @ Dec 29 2006, 03:48 PM) *

your neighbors are gonna hate you! (IMG:style_emoticons/default/laugh.gif) (IMG:style_emoticons/default/Jumpy.gif) (IMG:style_emoticons/default/w00t2.gif) (IMG:style_emoticons/default/w00t1.gif)


I hope so!

LOUD PIPES SAVE LIVES (IMG:style_emoticons/default/smile.gif)

keep the little kids from running out in the street without looking (IMG:style_emoticons/default/smile.gif)


BTW - this gutted muffler is LIGHT!!! guessing no more than 15 lbs!
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tracks914
post Dec 29 2006, 07:52 PM
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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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tracks914
post Dec 29 2006, 07:52 PM
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Drilled...


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tracks914
post Dec 29 2006, 07:54 PM
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Stainless Steel...


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tracks914
post Dec 29 2006, 07:56 PM
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Side view..


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tracks914
post Dec 29 2006, 08:02 PM
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and installed when I can find the picture...
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alpha434
post Dec 29 2006, 08:15 PM
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Dude. Cool.
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Crazyhippy
post Dec 29 2006, 09:16 PM
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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??
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Aaron Cox
post Dec 30 2006, 12:08 AM
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i havent made the caps yet...

i have a brand new tip for the stock outlet (IMG:style_emoticons/default/smile.gif)

the thing is gonna get sanded/painted/por20'd after craigs friend gets done welding it (IMG:style_emoticons/default/smile.gif)
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