Problem with SSIs + Dansk 2-in 1-out. Will this fit in car?

[Discseven]

I’ve got new SSIs (91.917SSI) installed on a 3.2 and am putting a 2-in 1-out Dansk muffler (1620607900) onto those. Early test fit of these parts (engine was on a stand) proved the pipes and bolt holes aligned. Now with the saddle installed on the engine the muffler will not meet up with the SSI pipes because the saddle is in the way. SSI or muffler pipes are too short. I thought about bashing the muffler in to make the necessary clearance but decided against this. Gentler plan is to make and put spacers between the SSIs and muffler.

…This would position the muffler almost 1” further back in the car. Car is an ‘80 SC. Question is: Will moving this Dansk muffler back 1” fit into muffler cavity in an ‘80 SC?

PS. If you have done this mod with a 3.2 in an SC, how did you handle the hanger?

[dg567]

Are you using the correct Dansk muffler that has the indentation for the 3.2 muffler hanger?

[917_Langheck]

Based on the part number it looks like this one:

https://www.pelicanparts.com/More_Info/91111102501.htm?pn=911-111-025-01-M350

[Discseven]

Originally Posted by dg567

Are you using the correct Dansk muffler that has the indentation for the 3.2 muffler hanger?

Muffler I was told would fit my 3.2 & '80 SC is Dansk's 1620607900. Has slight indent but nothing like the one you posted.

Goal is to make the parts I have work but if there's no space in the engine bay to move the Dansk back about 1", I'll have a wasted a good bit of time & money here. Also concerns me that the Dansk seems to sit higher than the stock muffler when on the engine---that's a guess based on my recall. So muffler height inside the engine bay is another concern.

Bottom line, I can make the parts to solve the fitment issues on the engine. But after that's done, will the "package" fit in the engine bay? Am not asking for you or anyone to take & supply me measurements. Am looking for someone who's gone this path before. Have you?

[$yncro]

I've installed SSI thick flange on my 80 3.0
And the problem I had was the engine won't
Go as far in due to the Dansk muffler tip sitting
High. It's hitting the lower valance. Solution
Was to cut the tip off and rotate welded so it's
Pointing down and it solved the problem.
Hope that helps in your situation.
BTW.. did you have thick flange SSI's?

[brianlay]

I have a Dansk Sport muffler on my 3.2 with SSIs.
As mentioned by DG567, I think you're trying to fit the wrong muffler.

[PeteKz]

I wasn't clear about which engine you have. If it's an SC expanded to 3.2, you don't need that big indentation. The hanger at the back of the SC engine has two ears that hook the muffler seam and get clamped under the two big muffler clamps. I have a 1973, so I don't have any room to move the muffler back. You may have more room in your car.

[Discseven]

Originally Posted by $yncro

I've installed SSI thick flange on my 80 3.0
And the problem I had was the engine won't
Go as far in due to the Dansk muffler tip sitting
High. It's hitting the lower valance. Solution
Was to cut the tip off and rotate welded so it's
Pointing down and it solved the problem.
Hope that helps in your situation.
BTW.. did you have thick flange SSI's?

That's a fine solution $yncro but is not what I've got in hand. Muffler and SSIs are not reaching each other because the muffler is butting against the saddle.

I believe the flanges are "thick." Were they thicker it might be better!

Originally Posted by brianlay

I have a Dansk Sport muffler on my 3.2 with SSIs.
As mentioned by DG567, I think you're trying to fit the wrong muffler.

Is indeed possible the muffler is wrong. Someone suggested 964 cams + SSIs + Dansk was a good tweak for a 3.2. Fellow who told me this knows this stuff inside & out supposedly so I trusted the part numbers he provided me.

If you happen to know the muffler part number you used Brian... I'd greatly appreciated knowing what it is. If push comes to shove, I might bite the bullet and get what you got.

Originally Posted by PeteKz

I wasn't clear about which engine you have. If it's an SC expanded to 3.2, you don't need that big indentation. The hanger at the back of the SC engine has two ears that hook the muffler seam and get clamped under the two big muffler clamps. I have a 1973, so I don't have any room to move the muffler back. You may have more room in your car.

It's a 3.2 in an '80 SC Pete. With the muffler butting against the saddle and not reaching the SSIs, that puzzle needs solving before dealing with the hanger---hanger might also might not fit! Is a slam dunk to add spacers between the SSIs and muffler but I don't know the cavity space well enough in the engine bay to make a call on whether moving the muffler back will work or not. I believe the Dansk unit I have is chubbier than the stock muffler that came out so already there's less space in the rear of the car than there was.

You might be wondering why I don't just take some measures and sort this out. I'd do that but have moved the engine from my place to the garage where it will go back in the car (and car is sitting in my garage.) Thursday I'll get to the engine to put eyeballs back on this. Until then, am looking for what others have experienced with this. It feels like I got the wrong muffler.

[dg567]

This muffler for the 3.2 is PN 1620611600, I believe. Its available in a few options, steel, stainless. 60mm or 84mm muffler outlet. Make sure you order the one you want if you decide to order a new one.

I think if you use spacers you'll run into clearance issues when you go to install the engine, you may have to remove the rear bumper and it still may interfere with the bumper when you reinstall it. Its pretty tight in there as it is.

[brianlay]

Part number on mine is 92.512S

From the Dansk catalog, looks like your muffler is for a 2.7/3.0

Mine is the 84mm variant, they are also available with a loose tip version as well

[Discseven]

Originally Posted by dg567

This muffler for the 3.2 is PN 1620611600, I believe. Its available in a few options, steel, stainless. 60mm or 84mm muffler outlet. Make sure you order the one you want if you decide to order a new one.

I think if you use spacers you'll run into clearance issues when you go to install the engine, you may have to remove the rear bumper and it still may interfere with the bumper when you reinstall it. Its pretty tight in there as it is.

Originally Posted by brianlay

Part number on mine is 92.512S

From the Dansk catalog, looks like your muffler is for a 2.7/3.0 Mine is the 84mm variant, they are also available with a loose tip version as well.

Thank you DG... Brian. Much appreciated! I believe "my adviser" did mention getting the 2.7 muffler---was more than a year ago this journey started so those conversations are fuzzy at this point. Config in photo looks right on. Muffler I'm working with clearly has no notch to go around the saddle. And that's the hanger I have. So you hit it nicely.

Now to sort out what to do. If this were small change, it'd be a no brainer to get a new part. Will put eyes on engine Thursday and see if it's at all possible to make what I have work. Mod might be "aggressive." Am not wanting to do the bumper program so thanks for the heads up on the spacer program DG. I'll have a look at the "situation" and get back to thread by Friday morning.

I do see the parts come with the different outlet options. Any opinion as to what each size does?

[dg567]

Originally Posted by Discseven

Thank you DG... Brian. Much appreciated! I believe "my adviser" did mention getting the 2.7 muffler---was more than a year ago this journey started so those conversations are fuzzy at this point. Config in photo looks right on. Muffler I'm working with clearly has no notch to go around the saddle. And that's the hanger I have. So you hit it nicely.

Now to sort out what to do. If this were small change, it'd be a no brainer to get a new part. Will put eyes on engine Thursday and see if it's at all possible to make what I have work. Mod might be "aggressive." Am not wanting to do the bumper program so thanks for the heads up on the spacer program DG. I'll have a look at the "situation" and get back to thread by Friday morning.

I do see the parts come with the different outlet options. Any opinion as to what each size does?

The different outlets are just cosmetic, the 70mm outlet allows you to use an original black muffler tip if you want the factory look.

[Discseven]

Originally Posted by dg567

The different outlets are just cosmetic, the 70mm outlet allows you to use an original black muffler tip if you want the factory look.

Thanks DG.

[Discseven]

Dansk (wrong part) bolted to SSIs without gaskets between them. Dansk’s seam has been bent down to allow muf to clear the saddle. Muf's indent is just not enough—parts are touching. Rather than get another new muffler, will increase the indent slightly. That + the gaskets and there'll be a few mm of clearance.






ID on muffler. What NOT to get for 3.2.








Hanger doesn’t fit. Needs to be lower. From Dansk’s seam center to saddle’s bolt center… am making this 49mm. Preliminary fitting suggests wrap of hanger’s lips over muf’s seam works as is allowing for inclusion of gaskets. Need to confirm this fit once installed. If the hanger’s lip-to-seam fit is good, adding spacers between SSIs and muffler would have required equal spacers between hanger & saddle.

Material hanging below the saddle… trimmed it. (Dremel with disk cutter.) Have second thoughts about doing this. Whether the strength of this part has been compromised too much or I’m over thinking it remains to be seen. (Will keep an eye on it when in op.)

EDIT: Looking at this, occurs to me that the indent on the hanger for the AC bracket that mounts to the saddle... that indent has been lowered about 25mm. My engine has that AC bracket. I doubt lowering this hanger is going to work. Will see. How the AC bracket and hanger indent set up can be seen in Brian's photo, post #10.

[Discseven]

^ Doesn't work.

[Discseven]

Continuing the effort...



Used Tinkercad to draw. Saved as SVG then converted to EPS in CloudConvert. Uploaded to SendCutSend. Outputting in .187" 316 series stainless. $69. shipped.

[Discseven]

Originally Posted by Discseven

Continuing the effort...



Used Tinkercad to draw. Saved as SVG then converted to EPS in CloudConvert. Uploaded to SendCutSend. Outputting in .187" 316 series stainless. $69. shipped.

Discussions with SendCutSend ended in my redrawing the bracket in Onshape. Tinkercad files render curves with many plot points resulting in cuts that are there but have a torn look. Here's an 1/2" aluminum part they just laser cut for me from a Tinkercad file...




Here's 3/16" stainless steel part also laser cut from an Onshape file. Vector based curves make big difference.





Wanted more vertical measure in the arms. Had to compromise on measurements given environment this is in. Think this will quench movement of exhaust pipes at the heads. Whether muffler will still want to move (flex-pivot at the flanges) and so find failure at the pipes that go from the muf to the flange... that's in question. Maybe I'm overthinking it.

.

[Discseven]

Could have had 5/8" more meat across the depth of the span and 3/8" longer on each side. Not doing over for the time being. Will see what comes of this. Straps wrapping the muf are absent here. Whether this will be a problem also has to be seen.
.