Sport Muffler Installation

[cegerer]

Installed a 2-out sport muffler today (what a PITA that was!). Anyway, it's just a trial fit right now. Took it out for a test run and am very pleased. Noticeable power/response increase. Now I'll take it back off to cut the pipe length down about 6 inches and paint.

Anybody got any tricks for installing the muffler bands?? I couldn't get them to slide over the hangers so I just left them off for the test run. Not much room back there to work with! -- Curt

[Joe911]

Similar power increase when I installed one. I would be interested if there is any noticable difference with the shorter pipes. I am always dinging my shins on mine. My "trick" on the muffler straps was to use large hose clamps I got at Home Depot = $1.75 each - look just like the $$ ones as I turned them so the screw is way out of sight!

[Scott Clarke]

Install your muffler bands with longer bolts, then remove one long bolt and replace it with the correct bolt. The other should then be easy to replace.
-Scott

[Vipergrün]

Yeah, longer bolts do the trick. If you wanna stay OEM-like, you should be able to source some SS allen head ones at a Marine parts store. Or, the swap trick works too. As far as the pipe length goes, I cut 4" off mine so they stick out only as far as the bumper pads. I only hit the hot pipes once........once

[pl69911]

Saftey wire works great to get the muffler bands close enough to get the bolt in ...

[724doorE]

Curt, what brand of sport muffler did you choose?

[cegerer]

Thanks for the tips guys. Dennis, I think it's a Dansk, but doesn't really say - somewhat crude to be honest. Obviously, a single out modified to 2-out. BUt the part that shows looks good! It is fairly loud, particularly when you step on the 'loud' pedal, but what a great sound. Even at idle & low RPM with the Solex cams it sounds really good. NOt sure what will happen when I shorten the tail pipes a bit. Will probably know this weekend. -- Curt

[724doorE]

Yea, I remember being told that my old one was tooDamn loud many times, I think I need another one

[TYPE 901/05]

Our bboard host company sells a two out sport muffler. Anyone know just how loud that little guy is when installed on a...say 67 2.0 liter?

Are we talking about Harley Davidson dragpipe loud or Mitsubishi with big ol coffee can megaphone out back loud? The kind that makes the neighbors cringe during early morning warm ups and late evening arrivals loud?

I want one, I just have no point of reference as to hair raising hot rod loud or the nice warmed over rumble...well 2.0 liter rumble.

Honestly, I don't really wish to announce an on power missed shift or carb stumble to the entire 1/4 mile radius, but I want a better on board stereo.

Shawn.

[cegerer]

Shawn, I don't really think it's THAT loud. The Harley guys still drown you out when side-by-side. -- Curt

[jpnovak]

Shawn, Its not too loud but the sound is just, well incredibly undescribably great. you should hear them at full throttle on the track. Music to my ears.

in reality, if you are using a well worn stock banana muffler, the sport mufflers have a different note, more bark, and are a bit louder. They are not nearly as loud as most sport compacts and no where near most V-twin motorcycles.

[Todd Simpson]

I've had mine for about a year and finally set off my first car alarm! The sound gets better as revs rise and is flat out unbelievable at 7K. Motor is a stock MFI 2.2S so yours should be even better.

[Vipergrün]

The Sport muffles *is* loud, but a pleasant loud. Even so, it was too loud for my neighbors at 5:30 in the morning I ended up putting in some removable Samson exhaust baffles like they use on Harley's. Now, I get the pleasure of the sound and performance without pi$$ing off the 'hood. Easily removable for the track.

[901/05]

Thanks guys...I am going to order one today. I promise to post pics when I get it installed.

Loud pipes save lives, Shawn.

[911SC Pilot]

Could we get a pic or 2, to see what you have done? Thanks

[Vipergrün]

Pilot - who are you asking?

[racemor]

Curt, I think we are going in opposite directions. I'm taking my 2-out off this weekend to replace it with a Dansk sport 1-out. I liked my 2-out but the quality was very poor. I purchased it from AJUSA and had problems from the start. The nice gray paint turned pink in the first 3 hours of driving and then started flaking off soon after followed by rusty welds. And I think even I could have done higher quality welds and I've not used a torch in 10 years. But the worst problem was the seam of the muffler started coming apart and filling the car with exhaust fumes scorching the paint at the center panel, eventually melting the rubber weather seal between the panel and the crossbrace at the back of the car.

So I removed the muffler to try and salvage it. Got the seam welded shut again, powdercoated it black and trimmed 3 inches from the pipes (preventing scraping on driveways). Much better! But now it has started resonating as though maybe a baffle is coming loose inside.

I was really surprised by the quality problems since both Halm and Paul Thomas have the same piece with out any problems. It seems like they rushed my order or farmed out the job or something. So I'm tring the Dansk sport 1-out. I'll be interested to see how the car responds and what the sound difference will be like.

Re: Are they loud? Girls say yes, guys just smile. Or ask my neighbors, I don't think they cared much for it cranking up at 6a.m. But I loved the sound, more loud Ducati/Yamaha than loud Harley.

[Tim Walsh]

Tom,
Your car gives me the whilies when you step on it... THere's a huge difference between my stock exhaust and your sport muffler. It's not loud like a v8 or harley oud but more describable as "purposeful" Not everyone likes it but I absolutely love that sound.

[skinnerd]

Bought AJUSA twin pipe 10 years ago. Quality OK from what I remember. Pipes way too long... hacksawed them off. Sent muffler out for JETHOT coating... never had issue with rust after that.

These mufflers really do sound incredible at full throttle... Had to tiptoe home late at not so as not to wake up the neighborhood though.

[cegerer]

Tom, I bought this new from a friend and he got it from AJUSA as well. The quality of the welds is not good - I might try to clean those up when I take it off. And the paint turned pink on my test drive (it must be gray primer!?)! I've now got special muffler paint from Stoddard and I'll give that a try when I remove it to cut the pipes down. Doesn't look like any seam problems. Had to really muscle the thing in to get it to line up with the heat exchangers - a real PITA. I'll post some pics before and after I remove it. For others, I'd be leary of ordering one of these from AJUSA - better to try Pelican!

Also, I've got a body shop guy fabricating a removable cover plate for the old 1-out exhaust opening from one of my fog light cover plates. It's already silver and textured and he's going to try to do it without repainting it. We'll use the black molding from the fog light cover as well. -- Curt