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-   -   Help me design a muffler for 3.6 varioram (http://forums.pelicanparts.com/porsche-911-technical-forum/1181119-help-me-design-muffler-3-6-varioram.html)

Duc Hunter 08-07-2025 11:26 AM

Ironically I have been taking to them as well. As JMZ says they only make a dual-inlet/Dual-outlet muffler in their X-pipe style. Since Bill V is of the opinion thats not good for our motors......that kind of sucks. "Progress." I hate it when companies take a perfectly good product, and change it for the sake of changing it. Probably did it as they use those resonators, and those X-pipes on lots of different exhausts, so it streamlines production speed and reduced costs. I do love my Fabspeed RSR system on my 3.2, that I put on it in 2015.

They want just under $2,000 for that setup, and they the told me it's only "slightly louder than the old suitcase style muffler."

Muffler looks like this one. This picture has cats up top and resonators on the bottom of the X I believe. A non-cat system would have resonators top and bottom. To my eye, and for my purposes (less noise), it seems like they could have a lot longer resonators, especially on the bottom....for the 964 and 3.2 style outlets. That would make the exhaust more quiet for sure.
https://cdn11.bigcommerce.com/s-fh9w...997868.jpg?c=2

They also said the 3.0, 3.2, and 3.6 RSR suitcase mufflers were all the same size and same size inlet and outlet pipes. Interesting.

David 08-07-2025 11:34 AM

I see this Fabspeed setup. Jay, did you ask what the header center to center dimension is on this?

With modified inlet and outlet pipes, this might work.

http://forums.pelicanparts.com/uploa...1754595142.jpg

targa72e 08-07-2025 12:26 PM

I have made a couple mufflers using products from Cone engineering.

https://www.coneeng.com/index.html

I have a similar header set up on my 964 and built my own muffler. I used two of their 4" x 12" muffler bodies welded together and the end caps. Connection is via V-band clamps. I used their merge collector on the headers as well.

.http://forums.pelicanparts.com/uploa...1754596760.jpg

http://forums.pelicanparts.com/uploa...1754596829.jpg


The inside of the muffler is a x design. All the straight sections internal to the mufflers were perforated tube. I used high temp packing made for off road motorcycle mufflers to stuff the case. drawing of internals.

http://forums.pelicanparts.com/uploa...1754597318.jpg


The first one like this I made was for my 996 turbo. I used the 10" wide cases for it.

http://forums.pelicanparts.com/uploa...1754597069.jpg

So you have a range of widths you can make the muffler and the tips.


http://forums.pelicanparts.com/uploa...1754597641.jpg

http://forums.pelicanparts.com/uploa...1754598097.jpg

I think they sound good and are not stupidly loud. They cost hundreds to make instead of thousands to buy.

john

Duc Hunter 08-07-2025 12:31 PM

Quote:

Originally Posted by David (Post 12511171)

David, yes they still show that one (suitcase style) in the pictures. When you call though they say they dont make them any more and don't have any. They replaced it with a dual resonator type with a X.

Bill Verburg 08-07-2025 01:20 PM

Quote:

Originally Posted by Duc Hunter (Post 12511167)
Ironically I have been taking to them as well. As JMZ says they only make a dual-inlet/Dual-outlet muffler in their X-pipe style. Since Bill V is of the opinion thats not good for our motors......that kind of sucks. "Progress." I hate it when companies take a perfectly good product, and change it for the sake of changing it. Probably did it as they use those resonators, and those X-pipes on lots of different exhausts, so it streamlines production speed and reduced costs. I do love my Fabspeed RSR system on my 3.2, that I put on it in 2015.

They want just under $2,000 for that setup, and they the told me it's only "slightly louder than the old suitcase style muffler."

Muffler looks like this one. This picture has cats up top and resonators on the bottom of the X I believe. A non-cat system would have resonators top and bottom. To my eye, and for my purposes (less noise), it seems like they could have a lot longer resonators, especially on the bottom....for the 964 and 3.2 style outlets. That would make the exhaust more quiet for sure.
https://cdn11.bigcommerce.com/s-fh9w...997868.jpg?c=2

They also said the 3.0, 3.2, and 3.6 RSR suitcase mufflers were all the same size and same size inlet and outlet pipes. Interesting.

It's not necessarily bad, just that many of the specific designs are poorly done and that is bad

The Fabspeed X pictures is one of the better implementations. In a poorly made system the 2 sides crash head on into ech other, In the Fabspeed they are parallel to each other at the connection.

Think about the gas flow
http://forums.pelicanparts.com/uploa...1754600740.jpg

When the sides are kept separate there is a nice partial vacuum between the pulses of gas
http://forums.pelicanparts.com/uploa...1754600740.png

when all cylinders are joined the space & pressure between them is degraded so that they interfere w/ each other to a greater extent.

http://forums.pelicanparts.com/uploa...1754601119.png

as long as there are 2 parallel flows this is alleviated, and the faster acoustic signals are better dispersed, this helps suppress the dB levels.

sound suppression is all about giving the gas room to expand and slow w/o impeding flow, the more room there is the better this aim can be accomplished.

another view of 911 6 flow patterns
general picture
http://forums.pelicanparts.com/uploa...1754601537.jpg

993 specific
http://forums.pelicanparts.com/uploa...1754601537.gif

993RS close up
http://forums.pelicanparts.com/uploa...1754601537.gif

David 08-25-2025 05:45 AM

Final muffler setup just waiting on the welder to tack it all together.

http://forums.pelicanparts.com/uploa...1756129294.JPG

http://forums.pelicanparts.com/uploa...1756129294.JPG


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