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.

I hope so!

LOUD PIPES SAVE LIVES

keep the little kids from running out in the street without looking


BTW - this gutted muffler is LIGHT!!! guessing no more than 15 lbs!

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.

Drilled...

Stainless Steel...

Side view..

and installed when I can find the picture...

Dude. Cool.

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??

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

Looking good.

That should be enough to spray headers and a muffler. Use Lacquer thinner to thin. I did a complete set of -6 headers and my sport muffler with that. Now you have to find someone to squirt it for you.

Hey Aaron I'll volunteer to do that for ya

no good deed goes unpunished craig LOL

eric - you sprayed it? i was thinking of just brushing it. it says it 'self levels' and the brushmarks 'cook out'.

i got the laquer thinner - and apparently craig is mah shooter

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...

But how does it sound??

Looks good.

BJH

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....

That looks great! Guud job.

So it's a bit loud still....

BJH

Nifty!

Nicely done.

It's 2007

school is back in... and getting in the way...

i got a Gas cap project, and a GT lid to paint too....

help me...

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

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

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?

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

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

Looks like bolts....

Damn i'm good

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

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

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?

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.

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

Velcro?
Duct Tape?

BJH

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....

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

head hurts.... 5 subject brain gang bang already today...

care to make it less painful?

you could do that too, i've seen something like that, where did i see it? hmm

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

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.

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

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

You mean he finally finished it??

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

pics before its painted....

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

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

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

I smell a CLASSIC!

congrats to you Aaron!

sure! when it comes off in the upcoming weeks to get painted w/ POR 20.. ill take a pic of the mount...

really simple