Muffler Install Problem
 

I am taking off an old bursch system on my 88 Carrera. Installing a Dansk "one in one out". this necessitated replacing the muffler to engine bracket, and the two straps that hold the bracket to the muffler. Problem is the right side or passenger side strap is too big and will not tighten up if I use it. I noted it is the larger of the two straps ,which was odd that the straps are different. they are all pelican parts. my only thought is to place something in between the strap and the muffler to take up space. this is a bummer as the entire setup is new. Pelican confirms the part numbers are correct. any advice ??

If the smaller one fits both sides, order another one of those......otherwise, have the strap cut and welded.

That is what I end up doing as I did not have a welding machine.

Now that I got one, I'll short it as mention by JB and shave a few ounces...

Isn't the larger strap supposed to also attach around the ventilation pipe that goes between the heat exchangers ?

clamp
 

Yes the larger one also goes around the heater crossover pipe.

I just talked to bruce at pelican and he was telling me that bracket 93011116406 is an additional bracket that I should have on there. that would explain the larger strap. I thought the above bracket was for the turbo. of course they want $90 for it. it was my impression that both straps would attach to that one bracket in the middle. ??

I'm not sure this will help with your muffler, but for what it's worth...with a stock muffler and heat, the two straps are different lengths but do bolt to the same bracket. On the drivers side, the shorter strap just goes around the muffler and the bracket. On the passengers side, the longer strap, as noted above, goes around the muffler, the SS heat pipe, and the bracket. I can try to take some pictures later and post tomorrow if that would help.

are we talking about that SS tube that goes from each side and up to the fan in the engine compartment? there is no way that the strap they sent me would go around that pipe and the muffler? then it occurred to me. does the strap go around a bracket welded to the SS tube or around the whole tube. it looks like a bracket may have been there at one time.

There should be one bracket bolted to the engine case, with two "wings" that the straps go around. If they sent you the correct straps, the one on the passenger side does in fact go around the 3" (approx?) SS tube that sends air from the heater blower fan in the engine bay to the heat exchangers and then on to the footwell blowers. I'll try to take some pics in the morning. Watching the Cubbies right now.

This pipe may not be there if the OP car has "back date heat".

Agreed. I was a little hesitant initially to post a reply not knowing if the OP's car is stock, but I did note that my comments would only apply to a car with stock muffler and heat (i.e. not backdated).

So, at the risk of adding more confusion rather than clarifying, here are a few photos from a stock 88, non-turbo.

http://forums.pelicanparts.com/uploa...1478179416.jpg


http://forums.pelicanparts.com/uploa...1478179429.jpg

As noted, the longer strap on the passenger side goes around the heat tube. There isn't an additional bracket (2A) on the PET page below. Both straps go around Bracket 2.

http://forums.pelicanparts.com/uploa...1478179504.jpg

This is interesting because the Pelican catalog shows 2A as for a turbo, but my PET shows it for M559/573 which I believe is the option code for A/C. Anyway I don't have it, so I'm inclined to believe it's for a turbo or is just missing.

I do however, have a bracket (more of a guide really) welded to the heat tube on the drivers side (shorter strap) as highlighted in the PET page below, and as I tried to show in the following picture. Pictures aren't the best as I'm trying to get under the car without a lift.

http://forums.pelicanparts.com/uploa...1478179647.jpg


http://forums.pelicanparts.com/uploa...1478179666.jpg

Finally, I wanted to use all SS straps and hardware, so I bought a set from ebay similar to this...

Porsche 911 84-89 Carrera Muffler Strap & Bolt Set | eBay

Here they are installed...



Hope this helps.http://forums.pelicanparts.com/uploa...1478179862.jpg

big help
 

Thanks John, your photo's were a big help. Not having seen an original system it would never have occurred to me to assemble it as shown. After two hours of taking things off and putting them back on, I now have an original looking system. The Germans never cease to amaze me in what they design. Big thanks again to you and all the other Pelicans who gave me advice.

You're welcome. I know I've gotten much more from the Pelican community that I've given, so I'm glad to help on occasions that I actually can.

One of the things I keep in my shop is a "Make-A-Clamp" kit by Breeze. It allows you to cut the straps to any length you want and quickly make clamps of any size. Been using them for years so I can change things up without having a to worry about the clamp portion of the task.