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(the shotguns)
Join Date: Feb 2006
Location: Maryland
Posts: 21,620
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what's the secret to drilling the holes for new '2 out' pipes for sport muffler?
How exactly do you drill the 2" holes to make a sport muffler (for the two new outlets) without some sort of fixture to keep them straight?
One thing i have learned from my limited welding experience is that the tighter the fit the less likely i am to burn holes and make a total mess.
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***************************************** Well i had #6 adjusted perfectly but then just before i tightened it a butterfly in Zimbabwe farted and now i have to start all over again! I believe we all make mistakes but I will not validate your poor choices and/or perversions and subsidize the results your actions. |
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10-06-2008, 05:13 AM
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use a hole saw for the size pipe you want it should be close enough to get a good weld on. Plus you can lay out the pilot holes easily.
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Ben 89 944,85.5 944 914-6 2.4s GT tribute. 914-6werkshop.com |
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10-06-2008, 05:20 AM
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That's what I did for my muffler. I set the muffler on top of a couple of large jack stands so that I would be drilling straight down, it's easier to eyeball it this way. There will be a little bit of play with the hole anyway, I used a prybar in the pipe to tweak them a bit to get them straight.
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Michael Sans Porsche...for now 2009 Mazdaspeed 3 Grand Touring daily driver / DS autocross toy 2010 Subaru Forester X Limited - wife's daily driver |
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10-06-2008, 05:24 AM
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(the shotguns)
Join Date: Feb 2006
Location: Maryland
Posts: 21,620
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but how did you guys keep the hole saw centered? i guess the centering bit was long enough to do its job?
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***************************************** Well i had #6 adjusted perfectly but then just before i tightened it a butterfly in Zimbabwe farted and now i have to start all over again! I believe we all make mistakes but I will not validate your poor choices and/or perversions and subsidize the results your actions. |
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10-06-2008, 05:30 AM
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I was doing more of a GT3-style muffler with the tips closer together but I simply used blue masking tape to map out where I wanted the holes, then marked the center, drilled a small diameter pilot hole, and then went to work with the hole saw. The pilot bit on the hole saw will keep it centered most of the way until you cut through the majority of the sheetmetal body of the muffler, then it's brute force. I had to take the grinder to mine to clean up the openings a little bit, but it worked out fine.
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Michael Sans Porsche...for now 2009 Mazdaspeed 3 Grand Touring daily driver / DS autocross toy 2010 Subaru Forester X Limited - wife's daily driver |
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10-06-2008, 05:33 AM
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Registered
Join Date: Dec 2001
Location: Dayton, OH
Posts: 342
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plasma cutter.
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10-06-2008, 05:46 AM
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Less brakes, more gas!
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Beaver Teeth
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 Michael '82 Euro SC 'Track Rat' 22/29 Hollows, 22/22 Tarrets, Full ERPB F/R, Rennline Tri Brace, Glass bumpers, Pro 2000's, 5 pts, blah blah blah '13 Cayenne GTS |
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10-06-2008, 08:29 AM
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AutoBahned
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punch/drill small hole - move hole cutter or buy longer center drill for it
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10-06-2008, 09:33 AM
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Registered
Join Date: Jan 2002
Location: Long Beach CA, the sewer by the sea.
Posts: 37,708
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First, fit the pipes to the muffler. Then trace the oblong hole. Is there any other way? You can make more outlet pipes; you get one chance at the hole.
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10-06-2008, 11:22 AM
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(the shotguns)
Join Date: Feb 2006
Location: Maryland
Posts: 21,620
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good point Milt. common sense often eludes me when working on projects like this.
perhaps i'll start w/ 2 1/4" and if the hole ends up a touch large i'll bump to 2.5".
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***************************************** Well i had #6 adjusted perfectly but then just before i tightened it a butterfly in Zimbabwe farted and now i have to start all over again! I believe we all make mistakes but I will not validate your poor choices and/or perversions and subsidize the results your actions. |
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10-06-2008, 11:36 AM
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Quote:
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Ben 89 944,85.5 944 914-6 2.4s GT tribute. 914-6werkshop.com |
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10-06-2008, 11:51 AM
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"farking Porsche hero"
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Keep in mind, once you drill a hole with a hole saw, you can't use a hole saw to enlarge it because there's no where for the pilot bit to bite into.
I would think with an oblong hole a angle grinder might be your friend. As long as you don't go oversize, the hole doesn't have to be perfect.
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Rich '66 911 #303872 '07 Cayman '17 Macan '58 Land Rover S2 88" |
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10-06-2008, 12:31 PM
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"farking Porsche hero"
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Never mind...I just noticed you're getting advice from the muffler guy.
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Rich '66 911 #303872 '07 Cayman '17 Macan '58 Land Rover S2 88" |
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10-06-2008, 12:32 PM
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Join Date: Feb 2008
Posts: 1,438
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Get a die grinder and sneak up to the opening you want. Trim the 2" pipe concurrently with the muffler hole and work them where they interfere. With a little back and forth fit checking you will have a pattern you can use for the second hole. You could get close by replicating the curvature of the muffler with a stiff paper model and do your initial sizing work there and then make a template without committing the muffler to your learning curve.
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Paul Abbott Weber service specialist www.PerformanceOriented.com |
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11-04-2008, 09:44 PM
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Join Date: Jul 2000
Location: So. Calif.
Posts: 19,910
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Create a slightly undersize hole using traditional methods, then bend the edges of the hole outward 90 deg. with vise-grips or equivalent. This will enlarge the hole slightly as well as provide a bit of overlap onto the tailpipe. When welding, the bent edge material provides filler material for the welded joint as well as add'l support for the new tailpipe.
Sherwood |
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11-04-2008, 11:14 PM
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My secret was to call Ben (mb911) and have him build the muffler from scratch. His welding skills are a LOT better than mine.
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Don Booth 87 Carrera Coupe (Current) 70 911 T Coupe 74 914 |
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11-05-2008, 02:09 AM
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(the shotguns)
Join Date: Feb 2006
Location: Maryland
Posts: 21,620
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Okay guys well i got it done and it turns out the holes were quite easy to do. And, as ben said, the hole doesn't need to be perfect to get a good weld going. nice relatively thick metal. MUCH easier than the welding i did with the pan sheet metal!
getting the pipes straight and level really wasn't that big a deal either surprisingly. for once a project went fairly well 
__________________
***************************************** Well i had #6 adjusted perfectly but then just before i tightened it a butterfly in Zimbabwe farted and now i have to start all over again! I believe we all make mistakes but I will not validate your poor choices and/or perversions and subsidize the results your actions. |
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11-05-2008, 02:40 AM
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Registered
Join Date: Jul 2000
Location: So. Calif.
Posts: 19,910
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Quote:
Sherwood |
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11-05-2008, 05:44 AM
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Designer King
Join Date: Mar 2004
Location: Toronto, ON Canada
Posts: 5,499
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Sounds like you did a great job!
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Paul Yellow 77 Sunroof Coupe/cork interior; 3.2L SS '80 engine/10.3:1/No O2; Carrera Tensioners; 11 Blade Fan; Turbo tie rods; Bilstein B6; 28 tube Cooler; SSI, Dansk; MSD/Blaster; 16x7" Fuchs/205/50 Firestone Firehawk Indy 500s; PCA/UCR, MID9 Never leave well enough alone |
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11-05-2008, 06:32 AM
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Ugly Betty
1966 Porsche 911
1987 Porsche 3.2 Carrera Coupe 3.2
