Thanks for the offer Ben. This is the kind of customer service that's given you your great reputation.

When you say quieter than ever, how much quieter is it than mine? I don't want too much quieter, just the mid range boominess after coming off the track. But I wouldn't want to do anything that would change how well this muffler flows.

Exactly......... I made 2 of them. One steel and one stainless. Simple job and $15 for parts and long as you own a welder.

Kevin

Ben,
I appreciate the offer. It is one which I will take you up on.

Emptyo,
Despite the rising cost of steel, you can buy cheap steel at supply houses. My local one has piles of scrap, which includes stainless. I can't imagine parts would cost more than $10. I sift through there occassionally.

Doug

Progress, Day 1.
 

So, I've officially made the plunge and started my RSR muffler conversion.

Here's the victim:


http://forums.pelicanparts.com/uploa...1215587138.jpg

And, turns out that front strut dust covers make great exhaust pipe donors. So, here are the donors to be (They would prove to come in handy later as well, for a completely different reason):


http://forums.pelicanparts.com/uploa...1215587248.jpg

First, lets mark the spot we need to cut so we can get to the baffles:


http://forums.pelicanparts.com/uploa...1215587303.jpg

Pry it open a bit, and expose the area to be cut:


http://forums.pelicanparts.com/uploa...1215587376.jpg

This hole saw would work for the bottom, but not the side. A nice 2" hole cut.


http://forums.pelicanparts.com/uploa...1215587420.jpg
http://forums.pelicanparts.com/uploa...1215587450.jpg

The side would prove to be a pain in the @ss. No real way to get a tool in there. I ended up using a smaller 2" cutting wheel attached to an air tool, cut three sides of a square, and torqued the piece back and forth until the steel weakened and finally broke. Then I took a small grinding wheel and rounded it off until I had an oblong hole of some sort. I didn't think the exact size or shape really mattered. If so, I guess I'm hosed. :)


http://forums.pelicanparts.com/uploa...1215587613.jpg
http://forums.pelicanparts.com/uploa...1215587632.jpg
http://forums.pelicanparts.com/uploa...1215587652.jpg

Progress, Day 1, part Deux
 

Welded up and ground down. I know...don't be jealous of my pigeon poop welds:


http://forums.pelicanparts.com/uploa...1215587803.jpg

Ok, now to cut off the current tailpipe:


http://forums.pelicanparts.com/uploa...1215587851.jpg

Easy enough. Here's where the cool part was for the evening...I didn't have any really good way to make a perfect circle to patch that spot. Turns out, my Koni strut dust covers were the exact same circumference as the stock hole. Score.

I ground off the spot welds and had a perfect patch for the muffler hole. After a little grinding and fitting, it was more pigeon poop welds and a bit of grinding.


http://forums.pelicanparts.com/uploa...1215587962.jpg
http://forums.pelicanparts.com/uploa...1215587981.jpg
http://forums.pelicanparts.com/uploa...1215588004.jpg

And, here is the final product, after a couple hours of work. I really spent a long time trying to figure out how to cut that left-side hole...otherwise it would have taken a little more than an hour to get to this point.


http://forums.pelicanparts.com/uploa...1215588077.jpg

tomorrow I'll prep the muffler and contemplate the pipes. There's a muffler place about 100 feet from where my car is, so I'm thinking about just taking it over there so the pipes are perfect. Even if they just cut the holes for me it would be a big help, as I have no idea how one might do that in this case. Will keep you posted.

Whch means I have a LOT of sanding to do. Which is why, of course, I did NO sanding today and finished my exhaust project. I'm almost more proud of it than anything I've done on the car. Besides, I hired a guy to help me sand for 10 bucks an hour. $100 WELL spent.

Ok...I'm in a hurry to go out, so in order:

1. Marking the holes
2. Drilling them out with hole saw
3. Test fit with Koni Yellow Strut Dust Covers (Lots of grinding happened in steps two and three.
4. Tack on the bench, quickly failed when I got out to the car. Duh.
5. Bring welder out to car, adjust fit, tack some more. The left side is 1/4" shorter than the right, but I'm going to shorten them anyway once I figure out what length I want.
6. Finish weld on Bench
7. Run to car to hear what it sounds like. :) (Video / Audio clip tomorrow)
8. Grind and clean, get ready for paint.
9. Using engine enamel, paint it factory RSR white.
10 Reassamble (for the 10th time today, probably) bumper and exhaust, and be stoked. Current state of affairs.


http://forums.pelicanparts.com/uploa...1215663442.jpg
http://forums.pelicanparts.com/uploa...1215663456.jpg
http://forums.pelicanparts.com/uploa...1215663467.jpg
http://forums.pelicanparts.com/uploa...1215663482.jpg
http://forums.pelicanparts.com/uploa...1215663501.jpg
http://forums.pelicanparts.com/uploa...1215663525.jpg
http://forums.pelicanparts.com/uploa...1215663552.jpg
http://forums.pelicanparts.com/uploa...1215663571.jpg
http://forums.pelicanparts.com/uploa...1215663606.jpg

http://forums.pelicanparts.com/uploa...1215663672.jpg
http://forums.pelicanparts.com/uploa...1215663684.jpg
http://forums.pelicanparts.com/uploa...1215663717.jpg
http://forums.pelicanparts.com/uploa...1215663730.jpg

looks good.. how many hours did it take just as I am curious?

Hey Ben,

Thanks, I'm pretty proud of it. It took me about 7 hours to get it to this point, but I'm a complete hack. If I had to do it again today, it would probably take me two or three hours. A lot of the time was taken by taking the bumper and exhaust on and off so many times. It's nowhere near as beautiful as one of yours, but I was about to sell this exhaust for $100, and I'm glad I didn't at this point. Anyone want to buy a 2 in, 2 out flowmaster? :)

Hey there is nothing wrong with DIY stuff. Infact thats what started my business some may remember as it all started with a picture on this forum and 4 years later here I am selling 4-600 mufflers a year. but nothing is more satisfing then doing the project your self that is why I built my own engine, painted my own car, and everything else involved. Heck even built a garage with no plans just to show that I could. and it turned out square and rigid. I think it looks great..

Ben, that's an awesome success story. Not unlike that of our host as well. Your work is top notch, so it's plain to see why you've done well. Besides, not everyone is as dumb as I am to attempt to make it myself. :)

where's the vid dude?

Damn it, I knew some rabble rouser would remind the group.

The truth is...I didn't get a chance to make a good vid today. I have a really short 5 second one I did yesterday, but I wanted to do a better one. I'll put the little one on.

Ok, like I said, it's short and sweet. I'm curious about what the high-pitched sound is...sounds like the fan to me.

Listen Here

Sounds great to me:D

I like the high pitched whirr. I agree with your fan thought. All Porsches seem to do that and I think it is cool with the deep, rough roar and the layered high-pitched scream.

Here's a better vid of the muffler:

<object width="425" height="344"><param name="movie" value="http://www.youtube.com/v/jmpc_PGpQKg&hl=en&fs=1"></param><param name="allowFullScreen" value="true"></param><embed src="http://www.youtube.com/v/jmpc_PGpQKg&hl=en&fs=1" type="application/x-shockwave-flash" allowfullscreen="true" width="425" height="344"></embed></object>