Fabricate air splitter and distributor tube to fit new M&K 2-1

[Hendog]

This is an ’87 3.2. I am replacing an old worn out B&B muffler which was fit to my SSI’s. Everything was done by the PO many years ago.


My new M&K 2 in 1 out will not mate with the SSI’s because the old air distributor tube gets in the way.


You’ll notice the B&B was “flat”, where the M&K bows towards the collectors. So now I have to create a new air distributor tube.


Bill Verburg posted this photo (calling Bill Verburg) in some other thread. It kind of shows his creation using SS tubing (and maybe something else?).


This is the current steel splitter and pipe.


I’m thinking of using SCEET tubing from Aircraft Spruce which is good to beyond 550 Degrees F. Does it get that hot at the muffler surface? Also, I will have to fabricate an air splitter coming down from the air downpipe; any good ideas on what to use/how to make it?

Thank you

[Bill Verburg]

I only did this w/ a couple of 964 and 993 motors installed in early chassis so no specific 3.2 experience. I went through multiple iterations finally settling on a stock 964 heat cross over tube w/ custom B&B headers designed for 964 heat in and 911 heat out, seen here


One of the early iterations was this one w/ SSIs


Another ran flex tube up through the rear bumper, but I can't find any pics of that one

[Hendog]

Thank you Bill. That’s just what I needed to get me thinking outside the box.

[Hendog]

I managed to resolve my air splitter problem: I'll get to that in a minute.
I had purchased a new OEM muffler hanger bracket because the old bracket supporting the B&B muffler did not work with my new M&K 2/1. But I was not happy the way the M&K hung on the new OEM bracket either.
This is the new OEM bracket;


So I fabricated a new bracket...


... which works great with the M&k


Now to get back to the air splitter. A friend came over and mocked up a cardboard solution to my air splitter.

Mock up air splitter...


Then another friend at work (aircraft industry) took the mock-up and made a box out of stainless steel, so I was pretty jazzed!!


Another guy at work offered to lazer etch it...




I tapped the holes in the box so I could hang it with M6-1.00x12 bolts through the engine tin. This is how it fits up to mate with the original air blower in the engine compartment.
from below...

from above.

[Hendog]

Once the air splitter was in place I drilled and tapped a hole in the underside of the bumper to hang a hose clamp. The bumper had 3 holes already there of which only 1 was useful to me (middle of the bumper), which is why I drilled/tapped another at the far end. I ran 2" ID galvanized flexible tubing. The splitter box has 2" OD pipe on it.


Then I hooked up the near end to the SSI heat exchanger with SCEET.


...and then the far end.


Reverse view


and finally with the M&K in place


So now I have heat again for those cool days/evenings.

[David Inc.]

That is some really nice work!

Also, where did you get those very fancy spring-loaded strap clamps for the muffler? That's a sharp look as well.

[Hendog]

Those spring clamps will come with your new muffler����

[Hendog]

and one more from the driver's side.



I realize I've installed the tubing in the "crumple zone", however only the flex pipe is attached to the bumper. The solid tubing that extends INTO that zone allows for 2 1/2" of bumper travel before it makes contact. It is definitely a risk, but I'll take it.