GT3 style - homemade...

[Milo2361]

well i really didnt feel like springing the 700 for the M&K although it would have been nice, i used a Borla XR1 racing muffler, one dynomax 180º pipe, some random pipe i had laying around, and the skills i learned in High School shop class. I think i came out pretty good.

really tough fitment, as i had to bring the exit from the cat back towards the drivers side a bit, then around going into the muffler. the outlet was easy, and i custom fabbed the dual tip myself because anything i could find on the internet ended up being too long or the wrong sizes so i didn't even bother.

before:


after Fabrication:


on the car:


total cost of $135. Id like to think i did pretty good.

[mickey356]

And I will be the first to say "You did good".

[Milo2361]

if i can find a decent video recording device i'll post a clip... sounds real good. kinda raspy, deeper sound - pretty loud but not outrageous. a little bit of drone from idle up to about 2200 rpm, but after that it goes away. i dont know too many who like to run their 911 down that low anyway.

[Trackrash]

Is that stainless steel? What type of welder did you use? You must have had an awesome shop teacher.

[Milo2361]

the muffler is stainless, but the pipes are aluminized steel - - i feel i need to put something on them to keep them from rusting but the BBQ paint i used on the last creation didn't work.

the welds on the tip look good cause i ground them flat incase they would still be in view . its a gasless flux core wire welder. very similar to mig minus the gas i guess. hard to keep a good bead because of it, and butt welding pipe to pipe isnt the easiest. the hardest part was welding the muffler to the pipe due to the differences in the metal thickness. they're a little ugly but sealed - the most important part. I am in the process of fabricating a bracket for more stability to put on the stock muffler bracket.

[Milo2361]

heres a couple of photos of the muffler when i got it.

it was SUPER heavy when i got it, weighing in at a whopping 9 pounds.

[Danny_Ocean]

Originally Posted by Milo2361

the hardest part was welding the muffler to the pipe due to the differences in the metal thickness.

I'd have to guess the hardest part was welding that shovel handle to the unit...

[Milo2361]

wow didn't even notice the placement of the picture! good catch

[Danny_Ocean]

Originally Posted by Milo2361

wow didn't even notice the placement of the picture! good catch

At first glance, I thought you were using that as an exhaust hanger (you did say "home made"...).

[flat6pilot]

Most car shops carry high-temp header paint. 800°F+ I use it, it seems to work good. No signs of rust yet.


Oh, and nice job!

[Geronimo '74]

looks great! Good job!

dimensions?
Angles?
Diameters?

[schumicat]

Griot's Garage sells high temp paint that holds up very well.

[kenikh]

Very well done! That Borla muffler is intriguing, since it isn't chambered. Nice find.

[Elombard]

You need some SSIs and do 1 on each side.

[Milo2361]

ideally i would have gone with SSI's and an M&K 2 in 2 out version, but thats a fairly large amount of money i dont really have to shell out on it. throttle response is a little better, or atleast it feels like it - - - it for sure sounds like it. as for Dimensions, all i can say is the diameters are 2 1/2 inch all around, and the muffler case is 12 inches long. the muffler has two 3 inch stubs of pipe which i had to cut off to about 1/2 inch. the pipe coming from the cat in to the muffler is a homemade concoction of a 30º slant cut on both sides of one stub, and a 90 that sort of somehow slipped over it, then i heated it and bent it down to weld it so i didnt have to bridge a gap. the diameter at that point isn't quite 2 1/2 inch but i don think its making too much of a difference.

made my bracket - an old electric fence post welded to a piece of flat iron, bolted to where the old A/C mount was and hoseclamped the post stub to the muffler.

[JonT]

Looking good Milo. BTW I had a buddy in college from Bayard. Eric Siegfried--great guy! I was there for his sister's wedding years ago--nice little town!

[Milo2361]

was his sister Kara Siegfried? Her mom was my 3rd grade teacher

[BigD9146gt]

Nice work! Your next assignment is to make a duel exhaust for a GTI that has an R32 body kit on it... please don't ask me why anyone would want to do this

[Wavey]

Nice work Milo, I like it!

[Milo2361]

i painted both front and rear valences black - the rear because i didn't want to chop my original one, and the used one i bought was white, and the front because it was BADLY rock chipped. upon stripping the front i discovered the PO(or one of the PO's) did a TERRIBLE bondo job where it looks like he hit a curb... I sanded it as smooth as i could get it in 3 hours - almost perfect but not quite... not like its clearly visible anyway. wish i could figure out how to get the back valence black under the accordions to make it match front and back better... i still think it looks all right.

wish i could find a CHEAP valence for the rear that curved around on both sides so i didnt have those holes that are meant for a dual exhaust on the sides... anyone have any ideas?