Muffler Install Questions

[georgeinhere]

So...after never really turning a wrench in my entire life...I started to do some bolt-on stuff on my motorcycles...fast forward to today and I have...

1. Back bumper off
2. Stock muffler and catalytic converter off.

I plan to replace the stock muffler/catalytic converter with a used Powerhaus muffler...purchased very inexpensively in perfect condition...

Issues so far:

1. When I pulled off the Catalytic Converter from the Turbo, the studs came off with the nuts...nothing broke but the nuts and studs are still together.
2. When I place the new muffler against the back bracket that held the catalytic converter, the fit isn't right and it seems to be pushing at an awkward angle on the muffler. Should I modify or buy a new bracket?

More questions:

1. Do I need to get a new gasket between the Turbo and the new muffler?
2. Should I get new Studs and bolts (one of the studs/nut is still attached to the catalytic converter and I haven't had any success being able to get it out).
3. There is a line that I disconnected from the back of the catalytic converter, what do I do with that line? New muffler does not have anywhere to hook it up to.

Thanks in advance for your time...it is kind of cool to have some grease on my hands!
I have no issues with getting the car towed to the P-mechanic but I'd like to have some pride left
George

[turbobrat930]

First of all, congrats on taking up the wrench...and doing things for yourself!!!

Second, I have never had a cat on my car...so I cant answer all of your questions..but I will try.

As far as the studs and nuts. Get all new studs. I use copper lock nuts that are either available from this site.. or EBS ( engine builders supply) use anti seeze when putting them back together.

2. I dont know about the bracket.

The air line that was attached to the cat is from your air pump, and is only for emmissions... clamp it... you will no longer need that line connected to anything ( unless you need your cat back on at some point to pass emissions)

[RarlyL8]

Yes, use new muffler gasket.
No, standard muffler bracket will likely not fit aftermarket muffler.
Yes, cap off the air injection line and tie it to fender brace to keep secure and out of way.

[georgeinhere]

Thank you for the feedback. In an ideal world, I'd buy Rarly8's Muffler/headers and turbo but cannot afford it right now...soon, I hope.
I am going to call Powerhaus to see if I just take off the bracket or if there is a "trick" to it.
When you guys say cap the air line...should I go back and take the smog pump off of the car and put it aside? Also, how do I go about capping the line?
Once again, thank you very much for the feedback...I am hoping to have it button up sometime within the next few days.
G.

[RarlyL8]

Yes get new studs and nuts.
You can remove your entire air injection assembly if you wish but may get into trouble with the fittings that bolt into the heads. If they have been there for 20 years (likely) then removal may be difficult. Many of my clients have collector level cars that are stock. When I remove the cat and muffler I clean them up and box them for storage. Don't box dirty or damp as that promotes rust. The main air injection line is then capped off with a tapered flange bolt and the air injection belt removed. I don't recall the size off hand but can get that for you.
The world if far from ideal right now. Used parts are plentiful and at good prices.

[georgeinhere]

Brian,
I spoke to you on the phone when I first purchased my car, you offered objective advice then as you continue to do so today. I look forward to doing business with you in the near future and wish nothing but great success on your new business venture. People like you are a dying breed...you're much appreciated.
Best,
George

[rsrfan]

The lower left "ear" on the US muffler bracket must be removed in order to fit the larger aftermarket can exhausts. Alternatively, you can order a "euro" exhaust bracket from our host. Either way you will need a new muffler strap as well.