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> Making a Sport muffler for a /4 Header, using a 911SC Muffler. Project "tri-tip"
Lou W
post Dec 30 2006, 02:08 AM
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Looking good. (IMG:style_emoticons/default/welder.gif) (IMG:style_emoticons/default/thumb3d.gif)
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Eric_Shea
post Dec 30 2006, 11:03 AM
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QUOTE
cute little thing of POR 20 came today.


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.
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craig downs
post Dec 30 2006, 07:53 PM
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QUOTE

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
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Aaron Cox
post Dec 31 2006, 12:25 AM
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QUOTE(craig downs @ Dec 30 2006, 05:53 PM) *

QUOTE

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 (IMG:style_emoticons/default/smile.gif)
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Aaron Cox
post Jan 7 2007, 06:48 PM
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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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Crazyhippy
post Jan 7 2007, 06:57 PM
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But how does it sound??

Looks good.

BJH
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Aaron Cox
post Jan 7 2007, 07:08 PM
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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....
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swood
post Jan 7 2007, 09:12 PM
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That looks great! Guud job.
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Crazyhippy
post Jan 7 2007, 09:27 PM
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QUOTE(Aaron Cox @ Jan 7 2007, 05:08 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....


So it's a bit loud still.... (IMG:style_emoticons/default/chairfall.gif)

BJH
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KaptKaos
post Jan 7 2007, 09:27 PM
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Nifty!

Nicely done.
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Eric_Shea
post Jan 7 2007, 10:36 PM
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It's 2007 (IMG:style_emoticons/default/yawn.gif)
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Aaron Cox
post Jan 7 2007, 10:39 PM
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QUOTE(Eric_Shea @ Jan 7 2007, 08:36 PM) *

It's 2007 (IMG:style_emoticons/default/yawn.gif)

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

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

help me...

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cnavarro
post Jan 8 2007, 09:03 AM
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Excellent thread. Now if someone made a muffler like that you could buy to replace the stock muffler...
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Aaron Cox
post Jan 8 2007, 10:06 AM
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and this is noticably lihghter than the stock eurorace street exhaust setup;
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Aaron Cox
post Jan 8 2007, 04:52 PM
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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....
(IMG:http://www.mcmaster.com/catalog/112/gfx/large/9275kp2l.gif)

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?
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Crazyhippy
post Jan 8 2007, 05:12 PM
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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
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Aaron Cox
post Jan 8 2007, 05:23 PM
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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 (IMG:style_emoticons/default/sad.gif)


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Crazyhippy
post Jan 8 2007, 05:29 PM
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Looks like bolts....

Damn i'm good (IMG:style_emoticons/default/biggrin.gif)

Have to worry about vibration too, every exhaust pulse will cause the plugs to pulse...
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Chris Pincetich
post Jan 8 2007, 07:23 PM
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This is an awesome project! (IMG:style_emoticons/default/smilie_pokal.gif)

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 (IMG:style_emoticons/default/beerchug.gif)
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Aaron Cox
post Jan 8 2007, 10:03 PM
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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?
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