Dansk 2-in/1-out Won't Fit 911SC w/SSI's - Tailpipe Extension/Bumper Interference

[Gordo2]

Bummer - I'm unable to install my new exhaust set up on my '83 SC; a Dansk 2-in/1-out mated to SSI's (new Dansk from eBay / used SSI's).

The muffler flanges won't line up with the SSI outlet flanges:
- On the tailpipe side, I can't raise the muffler flange high enough to mate to the SSI flange because the tailpipe extension makes contact / interferes with the rear bumper.

The Dansk stamp (on the muffler) shows its a "Type 92.210" - which seems to be their aluminized (vice stainless) muffler.

Looks like I'm going to have to bring it to a shop to have them cut off the tailpipe extension and re-weld on a tailpipe that has sharper downward angle to allow it to clear the bumper.

Searched Pelican: appears this is a semi-common problem with Dansk mufflers. Some have no problem with the Dansk fitment, others like myself - not so.

Did I simply buy the wrong muffler?

Gordo

[al lkosmal]

You have the wrong muffler....tailpipe is higher on an early 911 than mid-year and SC, if i remember correctly.

regards,
al

[cabmandone]

I was thinking about my chop and neck the tailpipe suggestion and it struck me you'll have to put a small extension on the muffler outlet to do that. If you don't want to chop on your new muffler, if the one I bought would work I'll send you mine and you could return the one you bought if the seller would take it back.

[toddu]

That should be the right type. Mine did not fit, but I have headers and inputs to muffler were cut off and new ones welded on. So, not entirely surprising it didn't fit (all fab'd with engine on the stand).

But, I cut the tailpipe off maybe 1 inch from where it exits muffler, installed the engine and then held the tailpipe up and drew some reference lines. Took pipe and muffler to a tig welder and looks perfect now.

I can snap pics if you want.

Todd

[patz]

Take the valance off, go to a muff shop, have the tips relocated.

[Gordo2]

Patz, I would drive it to the shop - but prefer not to. The muffler won't mount as is, and although I might think the open SSI's are kind of cool, others - probably not so much...

Todd, sounds like what I'm planning for the tailpipe; I found plenty of photo's showing how they should line up, but thanks for the photo offer.

My wife's going to drop the muffler off at a shop tomorrow. I'm working, but will give them a call to discuss the instructions that will be provided with the muffler:




I don't think the shop will need the car to fit / adjust the tailpipe - but will see what they say.

Gordo

[patz]

It will fit with the valance off, trust me. If not, tow it. If you don't have AAA, you will soon with an old Porsche.

[JJ 911SC]

Originally Posted by Gordo2

Patz, I would drive it to the shop - but prefer not to...
I don't think the shop will need the car to fit / adjust the tailpipe - but will see what they say.

Gordo

Take the car in, that way it will be perfectly fit which translate to time and money save.

[doswald]

Gordo, another option: where the muffler joins the SSIs, use a tapered gasket or insert (thinner at the bottom; thicker at the top)-this will angle the muffler down slightly. I had to do this on my Factory Five roadster.
dho

[toddu]

Gordo, I guess what I was trying to say was, cut the tail pipe off so you can mount everything without interference, then hold the tail pope rotates the way you like it and scribe a few lines across the cut so the shop knows how it all lines up. Guessing at an inch, or 7/8, etc. might make it look like it's hanging down to far.

Or, maybe I misinterpreted your plans. You drawings skills kick ass btw.

Todd

[Zaz]

I have the exact same issue (nice sketch Gordo), but I purchased the Dansk from our host (correct fitment for model/year), so I've opened a ticket and hopefully it will get sorted (been more than 30 days; I took a test drive with it...).

[Gordo2]

The muffler's in the wife's trunk, ready to head to the exhaust shop tomorrow & see how they want to proceed (looks like a good shop - I didn't even know I had a local custom exhaust shop until I looked it up last night).

Responses:

Patz:
- I took the valence off when I removed the old B&B system/before I tried to install the SSI's and Dansk. Trust me, this thing ain't fittin' unless I remove the bumper . If the shop wants me to bring in the vehicle - I'll put in some ear plugs and let it rip. Its only 6 or so miles away.

Todd:
I get ya. I assume the exhaust shop will chop saw the old tailpipe off, leaving an inch or so remaining / sticking out of the muffler -- then bend a new SS tailpipe to exit ~ 1" lower and expand the end to fit over the remaining inch of pipe and weld it up. Or at least that's what I would do (if I had the skills and tools...).

I think if the original tailpipe was cut and re-welded to clear the bumper, the outlet would point ~ 30° downward. Thanks for the drawing remark; engineering graphics at Kent State U about 25 years ago is finally paying off ...

doswald:
Don't believe a gasket is going to fix the offset between the the muffler and SSI flanges - it's pretty significant, but thanks.

Zaz:
Bummer. When I ran into the problem, I stopped and searched Pelican only to find that this is a relatively common problem with Dansk mufflers. On one thread, I read where a guy considered shipping his muffler back to the retailer for an exchange, but someone commented something like - why bother, it's hit or miss on what you'll get with the replacement. Hope your's turns out well.

Here's some threads on the topic (searched after I purchased the muffler..._:
muffler tip differance
Dansk Muffler...changing tips
Dansk Muffler workmanship bad, show me your tail pipe

Search Dansk - there's more.

Gordo

[gtc]

Like Al said to begin with, you have a longhood muffler. You need a '74 muffler.

[SiberianDVM]

Originally Posted by patz

It will fit with the valance off, trust me. If not, tow it. If you don't have AAA, you will soon with an old Porsche.

LOL! But it's the truth. First time I ever took my GF out in the '84, it stranded us 15 miles away from town. Took almost 2 hours to get a flatbed out there.

[Gordo2]

Originally Posted by gtc

Like Al said to begin with, you have a longhood muffler. You need a '74 muffler.

Gents - don't doubt you, just wondering how you can tell what fits what from Dansk part #'s.

Gordo

[Gordo2]

The exhaust shop told me I should just go ahead and cut the tailpipe off to clear the bumper and mount the muffler.

They didn't really care where I cut the tailpipe off - they plan to bend and install a new pipe and said they will probably cut the original down to where it mates with the muffler.

Bottom line - for correct fitment, they recommended I bring the vehicle in with the muffler mounted / didn't want to tack on a new pipe without knowing that it would fit appropriately.

Tailpipe gets the sawzall this weekend.

Gordo

[Trackrash]

Originally Posted by gtc

Like Al said to begin with, you have a longhood muffler. You need a '74 muffler.

The bumper was changed in '74. One year only 2 in 1 out with a different outlet.
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[MysticLlama]

Originally Posted by gtc

Like Al said to begin with, you have a longhood muffler. You need a '74 muffler.

gtc would be willing to reweld it for you to fit with a HF welder bought 5min before closing, but wants a full face mask this time as opposed to the $5 goggles and sunburn that happened on an unmentioned SC one time...

[RL technical]

You have the incorrect muffler take my advice, it should just sit on. Your muffler won't have the dimple in the centre of the muffler to clear the engine mount cradle. Don't hack up the muffler to get it to fit, you have to buy the correct one and it will bolt straight up.

[Gordo2]

Originally Posted by RL technical

You have the incorrect muffler take my advice, it should just sit on. Your muffler won't have the dimple in the centre of the muffler to clear the engine mount cradle. Don't hack up the muffler to get it to fit, you have to buy the correct one and it will bolt straight up.

Agree - I purchased the wrong muffler. Meanwhile, it would be helpful if Dansk stamped each muffler with a part number to differentiate between the '73 and earlier and the '74 on. The painted on "type" doesn't seem to tell you much about the muffler fitment.

BTW, oddly enough - the muffler does have a dimple in the center. I hacked off the tailpipe tonight and it fit right up.

Gordo