Considering where you live, with all the aerospace work done in the NW, would feel that you can find a good welder around. I would talk with JW and see if he does not have someone who he could pass along to you.

Agree with Denis about waiting until the engine is in the car. Get everything lined up and do it then.

JoeA

If you are not in a huge hurry I could weld the new peices on as this would be part of the deal when fitting my new muffler designs(prototypes). Up to you.

Not really....here's my daily driver. Twin trapps with sport cats upstream. Smog legal and quiet with 18 discs each.


http://forums.pelicanparts.com/uploa...1097592974.jpg

Paul,

I think the leak can be fixed fairly easily and inexpensively with what you already have ... and keep the 'sporterized' muffler, too, for, the future, since it doesn't appear to be in too bad shape, overall!

However, I think the fitting and initial tack welding should be done with the engine in the car for best future fit of mufflers to the car!

1. Get some new gaskets for the existing 911 flanges on the Triad.

2. Grind off the botched oversize tubing tacked over the original SSI collector. You will probably want to leave at least 3/8" of the existing SSI collector in place and not disturb the mating to individual cylinder tube runners.

3. Grind/cut the new collector tubes back until fit is within 1/16" gap of SSI collector 'ring' with repair pieces securely bolted to new Triad with proper gaskets in place. The new collectors will need to be trimmed back carefully, and painstakingly!!!

4. I think MIG with stainless wire would be satisfactory method for this repair, and someone should be able to bring their equipment to your car to do the work. After tacking the new collectors in 5-6 locations, the SSIs should be carefully removed from the engine to complete the welding job at each collector.

5. New 2" flanges for the 'sporterized' muffler can be fitted and welded in a similar fashion ... tack in place on the car, finish the welding off the car.

Goog luck!

Mike, I was going to go with the Supertrapps until the parts for my SSIs became available, they look great sticking out the back of your car. Fixing the SSIs & the cost of the Triad($225) will still be cheaper than installing the Supertrapps.

I really think my template is right on, I measured everything 3 times, but it seems that it may be a mute point now because a fellow local Pelican has offered to assist me, he has an extra short block & has a couple of tin bender friends that can weld stainless.

Paul,

Have you contacted SSI to see what they would charge to put the parts on there jig and fix it? If they can't help, I would wait. Even some of the stock parts I've use are not all the same dimension and I have to "make it work." With the block, make sure you have the engine tins (rear section) and engine console (muffler hangs on it) all installed before you cut and weld.

Good luck.

Another Update
 

I went against the consensus on this one & used my wood template idea. GregK1 from the board contacted me about the job & the next weekend I went over to his home, what a great guy.

First we cut the crappy flanges off my SSIs, then mounted an old HE Greg had to the template, then bolted the muffler up to it.
http://forums.pelicanparts.com/uploa...1098575123.jpg

Then we were able to determine which side was which as far as the ends. We cut & tacked the left side first. You can see in this photo that we didn't need to trim much off the SSI ends that John got me, the scrap is on the ground.

http://forums.pelicanparts.com/uploa...1098581786.jpg
Actually Greg did all the work, I just held stuff. Here's a pic of everything tacked up & ready to ship to the welder.
http://forums.pelicanparts.com/uploa...1098582065.jpg
Greg has a tin bender friend that welds stainless. He dropped everything off to last weekend & I picked it up today. It only cost me $50 for the welding. Here's a pic of one of the welds, considering that the surfaces weren't flush, I'm very happy with the craftsmanship.
http://forums.pelicanparts.com/uploa...1098582327.jpg
I couldn't wait to get it home to see if everything fit. My neighbor & I set it on the motor all in one piece, it fit perfect, I even made sure there was plenty of clearance for the engine tin. There is more space between the muffler & the motor than this pic indicates.
http://forums.pelicanparts.com/uploa...1098582717.jpg
I am extremely happy with the results, & would like to thank Greg for his help. He is true to the Pelican & it is a pleasure to know him.