Help installing a dansk sport muffler.

[gliding_serpent]

Hi folks. My 3.2 has SSI's that previously had a M+K installed. The (thick flange) SSI's were brand new as was the m+K. A factory exhaust hanger was attached to the bell housing in thr correct location to my eyes. I removed the M+K and replaced it with a dansk sport dual out (pipes coming off the sides). Now when I try to install the dansk, the center seam that should rest on the hangers is a good 1/2 above the hangers, and the flanges will just not mate properly, especially on the passengers side. The flanges will touch at the bottom, but not at the top, and the center seam of the dansk is now touching the bell housing.

My thought is that maybe the secondary pipes of the SSIs were bent up, and need to be brought back down. Another option would be to trim or bend the seam of the muffler where it is interfering with the bell housing.

Thoughts and experiences appreciated.

[gliding_serpent]

Here is a 3.0 that installed just fine.


Here is my problem.




Comparing the photos, by bracket is positioned properly on the raised/curved part of the bell housing... but that raised/curved part almost looks to be a different style to the SC above. Thus, making my bracket lower, and the clearance issues. Tomorrow I will take the muffler off and have a closer look.

Could this be it?

[gliding_serpent]

Hmmm... some reading revealed that there are three types of Dansk sport mufflers, one for longhoods, one for 74-SC (mine apparently), and one for Carreras (with the 84 inch pipes). To make the earlier ones work, you need flanges. Sucks to learn that now it that is the case. That might explain why my muffler flanges were slightly less then 2 inches ID.

Edit:

From Patric Motorsportss webpage: "Muffler (Sport) Polished Stainless Steel - 70 mm Dual Tail Pipes - (1974) PORSCHE 911 - DANSK (92.511SD)

+ Application Note: Some fitting modification required for (1975-1989) models with SSI Heat Exchangers"

Mine is also 992.511SD. So maybe I just need flanges?

[JohnJL]

Sorry I dont have an answer for you, but what did you do with that M&K? 2-in 2-out?

[gliding_serpent]

Originally Posted by JohnJL

Sorry I dont have an answer for you, but what did you do with that M&K? 2-in 2-out?

sold it for the same price I got my polished stainless dansk for.

[sp_cs]

I had to use flanges as spacers with SSIs on my 87 - FYI had to do the same with the turbo Thomas headers and Dansk I had too.

[gliding_serpent]

Nice. Thanks very much! Seems to be the status quoe then, and my next question has been answered in regards to flange size with your photo.

How do you like his muffler? My rage with the dansk last night had me thinking about his rsr muffler with "competition" internals. My sick rationalization process has begun.

[jpnovak]

The difference is the engine mount console. It is larger on the 3.2 Carrera and this necessitates a relief in the muffler. The muffler can is too large on top of the seam and interferes with the muffler fitup and flange alignment.

If its a used muffler then you can effectively "dent" the muffler to make it fit. Otherwise, get the correct muffler.

[sp_cs]

Originally Posted by gliding_serpent

Nice. Thanks very much! Seems to be the status quoe then, and my next question has been answered in regards to flange size with your photo.

How do you like his muffler? My rage with the dansk last night had me thinking about his rsr muffler with "competition" internals. My sick rationalization process has begun.

Mine isn't a turbo Thomas muffler, it's a DW Technik item from Germany. I hear good things about his oval shaped silencers/muffler - proper 911 sounds without any drone but just weren't available at the time of my need.

[McLaren-TAG]

I went with a Dansk dual center out and had the same problem you describe. What I did was modify the cross member support housing where the muffler was actually hitting.

Originally I slightly trimmed the seal around that area of the muffler to give me a little extra room but it still wasn't enough. Picture worth 1000 words.




Benefit, no flanges and lost about 3 ounces of dead weight from the engine support housing to the crossmember. Every ounce helps.

[brianlay]

I installed a 74 type muffler on my 3.2 with SSIs

I trimmed the muffler flange and reformed the bracket a bit to get everything to fit.

[gliding_serpent]

Mine is used. I will try to trim the seam, and fiddle with the muffler bracket. I may also get spacer flanges for the headers. The key will be clearance to my new, yet to be installed getty rear iroc style rs bumper, as it is snug. Test fitting is a two person job. I will verify that backing the muffler up a bit does not cause clearance issues.

Thanks for the help folks, but tag, i can not visualize what i am seeing. I see what you did with thw muffler support bracket, which is clever, but i can not visualize the housing changes. Do you have an angle shot?

[SilverWT]

As has been said above, the 3.2 engine mounting console is bigger than on an earlier car.

Here is a picture of both a sports and standard 3.2 muffler showing the much bigger indentation in the center, both above and below the center seam. The long indentation in the bottom half (at the top in the pic) is to accommodate the steel air distribution pipe for the 3.2 heating. You will also need this if you have the stock heating setup.


A big hammer is your friend!

Mark

[gliding_serpent]

My heat is backdated.

So here is another question... Are the internal diameters of the intake flanges/tubes on the mufflers different from year to year/model to model? I ask because ssi's are 2 inches id at the end, but my 74 sport muffler is slightly less.