Dansk sport muffler WAY off from fitting!

[TeeJayHoward]

I bought a Dansk Sport Muffler (Part #: 10-1010-157-M350) from our host for my '81 911SC, and it doesn't fit. JP Group Dansk shows that it fits my car as well, under part number 162606300. (Same site also shows that it fits a 3.2, which I thought had a different mounting mechanism?) If I tuck it up into the muffler cavity and bolt it down (with the straps that are too short) it is several inches too far "up" from the cat/test pipe. If I bolt it up to the test pipe, it hangs down WAY too low to be strapped to the muffler mounting mechanism. The strap cutouts on the lip are also set too far apart to match up with the muffler/strap mounting mechanism.









What gives? Bad muffler? Wrong part in the box? Wrong part for my car? Installer error?

[Jeff Higgins]

The flange on the muffler is supposed to sit on top of the two little "fingers" on the muffler mount, the ones the straps wrap around. Put that seam up on top of those fingers where it belongs, and the straps will be plenty long enough. That's where the muffler belongs. Darn near touching the rear engine tin. The fact that the "test pipe" does not match up to it with it in its proper position indicates a problem with the test pipe, or its installation, not the muffler.

[Mixed76]

Make sure your motor mounts aren't sagging

Sent from my Pixel 7 using Tapatalk

[TeeJayHoward]

Originally Posted by Jeff Higgins

The fact that the "test pipe" does not match up to it with it in its proper position indicates a problem with the test pipe, or its installation, not the muffler.

I could understand the (new) test pipe having a problem, but I'm not quite sold on that yet. The muffler strap cutouts are spread too far apart even if the muffler's sitting on those little saddle fingers - If I had to guess, I'd say they're at the correct distance for a 3.2. The muffler sitting so low would also match up with the 3.2's lower saddle. My current theory is that JP Dansk is advertising this 3.2 muffler as also being compatible with the 2.7 and 3.0 (TecDoc application), and Pelican got caught up in the middle.

edit: Yup, I'm almost positive the "This fits your car!" is wrong for the muffler. Why would a 3.0L muffler have a heater crossover pipe indentation?

[917_Langheck]

Also has the 3.2 saddle notch...

[MrBonus]

I had the exact same issue with my prior 3.2 with a Monty muffler. I kind of wonder if they are designed for the ROW straight through pipe. I had to get the muffler modified by a shop to get it to fit.

[macssc911]

Had the same issue when I was running a Dansk years ago wit straps, just bought longer bolts for straps all good

[Jeff Higgins]

It could very well be that you have a muffler intended for a 3.2. Regardless of whatever it is meant to fit, it is simply mounted far too low. Start with that and see where it leads. I bet if you try to put the valance back on, it won't fit.

Here is a properly positioned muffler on a 3.0 with SSI's. Notice the bottom of the muffler is above the bottoms of the heater boxes. Even on your single out heater boxes, your muffler should sit slightly above the bottoms of them as well. Notice also where the lower engine mount bolts are relative to the muffler. Easily visible just past the bottom of the muffler, just slightly higher. Yours are on the center seam of the muffler. Finally, notice how close the engine tin gets to the muffler out at the corners. It's hard to get a finger between the two. You could get your whole fist in the gap on yours.





So, yeah, definitely something funky going on. If it were me, I would mount it up sans test pipe, put the valance back on, see if the outlet lines up, and all of that. If all of that looks good, I would alter the test pipe to suit. There is a lot of wiggle room with the straps, so unless they just simply won't grab the mount fingers at all when they are in the slots, I'd cinch 'em up and see how they look.

[mikedsilva]

Originally Posted by TeeJayHoward

What gives? Bad muffler? Wrong part in the box? Wrong part for my car? Installer error?

It's a One in, One Out muffler.
My guess is you bolted the cat bypass to the "engine end" first.. then tried to get the muffler to line up.

My advice would be to loosen ALL the nuts on both ends of the bypass pipe. Position the muffler so the lip sits on the muffler mount, the tighted everything up again.

When you looses the 6 bolts that hold the cat bypass pipe to the heat exchanger and crossover pipe, there is so much slack in the flanges that you can change the angle drastically.

That's just my suggestion.

[TeeJayHoward]

Originally Posted by mikedsilva

It's a One in, One Out muffler.
My guess is you bolted the cat bypass to the "engine end" first.. then tried to get the muffler to line up.

My advice would be to loosen ALL the nuts on both ends of the bypass pipe. Position the muffler so the lip sits on the muffler mount, the tighted everything up again.

When you looses the 6 bolts that hold the cat bypass pipe to the heat exchanger and crossover pipe, there is so much slack in the flanges that you can change the angle drastically.

I tried your suggestion when the muffler didn't fit initially. The straps were too short to hold the muffler in, so it was held in place while I took this pic:


I can get a few mm of adjustment by loosening the engine-side bolts, but that's like 75-80mm off.

Regardless of whatever it is meant to fit, it is simply mounted far too low.

I bought the 3.2L hanger. We'll see where it sits the muffler at, but I'm inclined to agree. If you check out the muffler design, the flange is located even with the bottom of the muffler. Unless there's an S-shaped test pipe I'm supposed to be using, I'm not sure how I can mount it higher.

[BoxsterGT]

Best to return this to our host.

With all your documentation, they cannot refuse to take it back in exchange for a correct one.

And, they should pay for shipping, both ways.

Just my 2 cents.

Len

[TeeJayHoward]

Suppose I should have updated this… With the 3.2 hanger, it technically works. The passenger side sits high, but it does all strap in and fit.