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Crotchety Old Bastard
 
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A Solution to Muffler Fitment Issues with Headers

I've run into a few muffler fitment issues with customers who are using aftermarket headers, heat exchangers, and turbos.
It doesn't take much deviation from stock to throw off the angle of the turbo outlet. That angle is amplified by the length of the muffler body.

I've been working with Ben (M&K) to come up with a solution that will add adjustment without adding too much cost or potential failure points. This is what we have come up with for the stock outlet configuration. I am very pleased with it and will begin testing the system to find potential problems. Right now the only thing I don't like is the addition of 2 band clamps that will hold the tailpipe in place. It may be a small price to pay for custom perfect fitment.
It took me all of 15 minutes to remove my current muffler and install the modular unit - without jacking the car or removing the bumper or valance.









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RarlyL8 Motorsports / M&K Exhaust - 911/930 Exhaust Systems, Turbos, TiAL, CIS Mods/Rebuilds
'78 911SC Widebody, 930 engine, 915 Tranny, K27, SC Cams, RL8 Headers & GT3 Muffler. 350whp @ 0.75bar
Brian B. (256)536-9977 Service@MKExhaust Brian@RarlyL8
Old 02-19-2008, 06:05 AM
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Nice!
Brian any chance you will offer this in 2-out config for 930's ? (Somehow, Someway)
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1987 - 930 Grand Prix White, Not looking for crazy HP, just harmony!
Old 02-19-2008, 11:14 AM
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Brando
 
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notice the open hole in the valance?
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1977 911s. it's cool
Old 02-19-2008, 11:46 AM
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Macht Schnell
 
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Quote:
Originally Posted by quattrorunner View Post
notice the open hole in the valance?

He's a muffler designer and fits lots of different mufflers, including dual outlet ones.

Les
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---Les Garten---85 930, Andial IC, GHL Headers, Fabspeed Dual, K-27 HF2, 3.4 JE Full Finned 7.5:1 CR, 964 CAM'd, Carerra 3.2 Manifold Cut/Flipped, Tec3r, Siemans 55#, GSF Fuel Rails, Clewett Crank Trigger, Clewett Cam Trigger,Dual Plugged, ARP Head Studs/Rod Bolts, Clewett Wires.Tial 46mm WG, Tial 50mm BOV, WEVO Shifter,934 Boost Gauge, Wideband EGO Sensor/Gauge, C2T Head Gaskets, '88 MB 300TE,BMW R100RT
Old 02-19-2008, 11:54 AM
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Smart quod bastardus
 
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That looks great.
As some constructive criticism, I do have one improvement I think you could make that I noticed.
The slip joint for the tail pipe section should fit over the outside diameter of the tubing coming from the muffler. You have it slipping inside this expanded end. It works better for flow to have it the way I described, less likely to leak. You have it done correctly on the section that attaches to the muffler outlet.
I have 2 questions:
What is the price of this system?
Can you provide a sound file of what it sounds like while running?

Fred
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1979 930 Turbo....3.4L, 7.5to1 comp, SC cams, B&B intercooler, Snow Perf water/meth injection, Rarlyl8 headers, Garret GTX turbo, 36mm ported intakes, Innovate Auxbox/LM-1, custom Manually Adjustable wastegate housing (0.8-1.1bar),--running 0.7bar max
---"When you're racing it's life! Anything else either before or after, is just waiting"
Old 02-19-2008, 01:16 PM
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OOOh nice Brian you still have the muffler in the corner of the picture explaining what not to do with a BFH when mad!
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Old 02-19-2008, 01:48 PM
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Crotchety Old Bastard
 
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Dual outlet is going to be very tricky but I am going to work on it.

The hole in the valance is for my personal muffler, the original dual outlet prototype.

If you are going to call me a muffler designer please use parenthesis ( "muffler designer" ) Ha! I am a Chemist by education and quality manager by profession and do not profess to be an engineer or physicist.

Good eye Fred but there is a method to the madness. This is a prototype unit and it is easier for me to adjust and manipulate the tailpipe length in that configuration. In this case we need to add 1" to the tailpipe length to make it fully adjustable when the 180* pipe is rotated 45* in either direction. I'll talk to Ben when I'm all finished with fitment and we'll address any optimal flow and leak issues.

Prices are on my website listed below. The goal is to not have an increase in cost with this design.
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RarlyL8 Motorsports / M&K Exhaust - 911/930 Exhaust Systems, Turbos, TiAL, CIS Mods/Rebuilds
'78 911SC Widebody, 930 engine, 915 Tranny, K27, SC Cams, RL8 Headers & GT3 Muffler. 350whp @ 0.75bar
Brian B. (256)536-9977 Service@MKExhaust Brian@RarlyL8
Old 02-19-2008, 01:59 PM
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Quote:
Originally Posted by RarlyL8 View Post
Dual outlet is going to be very tricky but I am going to work on it.
Great! Think I will need it as a backup plan to my Zork.
I am getting the "Evil Eye" from neighbors when I fire up the 930 and proceed to set off their car alarms
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1987 - 930 Grand Prix White, Not looking for crazy HP, just harmony!
Old 02-19-2008, 02:10 PM
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Crotchety Old Bastard
 
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Yes, the Zork can be a bit too agressive for the neighborhood. I'm actually building a custom muffler right now that center exits like the Zork for a fellow who wants to use it with his 934 waste gate pipe. Should be pretty cool. I hope to finish that one this weekend and will post some pictures.

Sound bytes, that's a tough one. I have yet to hear a You-Tube or similar recording that comes anywhere near duplicating the actual sound level of a Zork. The videos make them sound tame, almost quiet. I cannot in good conscience produce something like that, it is misleading.

That beat up muffler is a keeper. I'd like to mount it on the wall as some sort of testament to the frustrations of trying to make something fit that just will never, ha!
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RarlyL8 Motorsports / M&K Exhaust - 911/930 Exhaust Systems, Turbos, TiAL, CIS Mods/Rebuilds
'78 911SC Widebody, 930 engine, 915 Tranny, K27, SC Cams, RL8 Headers & GT3 Muffler. 350whp @ 0.75bar
Brian B. (256)536-9977 Service@MKExhaust Brian@RarlyL8
Old 02-19-2008, 06:51 PM
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I can't wait to see the one that is a bitmore quiet than a zork but exits likeone.. that sounds like a winner!
Old 02-20-2008, 06:09 AM
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cycling has-been
 
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Brian, will that unit clear the B&B (with heat) oil tank?
Is that the tank from a euro system on yours?
Bill K
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Old 02-20-2008, 11:52 AM
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Quote:
Originally Posted by bkreigsr View Post
Brian, will that unit clear the B&B (with heat) oil tank?
Is that the tank from a euro system on yours?
Bill K
God I hope so I put so many slip joints in there that this muffler could darn near do jumping jacks But maybe Brian can confirm for us he is the designer and M&K just builds em
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Current project 73 914-6 Gt project rusteration 2.4
914-6werkshop.com ,heat exchangers, oil tanks, etc
Old 02-20-2008, 11:58 AM
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Crotchety Old Bastard
 
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The tank on my car is the stock Euro unit. I have 4 different turbo oil tanks that I use for fitment testing. This configuration should clear them all.
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RarlyL8 Motorsports / M&K Exhaust - 911/930 Exhaust Systems, Turbos, TiAL, CIS Mods/Rebuilds
'78 911SC Widebody, 930 engine, 915 Tranny, K27, SC Cams, RL8 Headers & GT3 Muffler. 350whp @ 0.75bar
Brian B. (256)536-9977 Service@MKExhaust Brian@RarlyL8
Old 02-20-2008, 12:12 PM
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cycling has-been
 
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Brian, here's a shot of the B&B tank. It would not clear the stock muffler. (excuse the clamp, I'm in the process of fitting different tips, and plan to get it stitched when I've settled on one.)

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Last edited by bkreigsr; 02-20-2008 at 03:38 PM..
Old 02-20-2008, 03:36 PM
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Crotchety Old Bastard
 
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That is correct, the B&B turbo oil tank is not compatable with the stock muffler.
Any aftermarket header or heat exchanger will require a non-stock turbo oil tank. The goal is for my muffler to be compatable with anything out there.
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RarlyL8 Motorsports / M&K Exhaust - 911/930 Exhaust Systems, Turbos, TiAL, CIS Mods/Rebuilds
'78 911SC Widebody, 930 engine, 915 Tranny, K27, SC Cams, RL8 Headers & GT3 Muffler. 350whp @ 0.75bar
Brian B. (256)536-9977 Service@MKExhaust Brian@RarlyL8
Old 02-20-2008, 06:50 PM
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