Dansk muffler doesn’t fit ssi on 3.2

[Gideon911]

Hey guys, I’m sure many of you know this and have seen it talked about. I bought a 2 in 2 out dansk exhaust for my 3.2 88 with ssi. The flanges do not match up. Is there an muffler that I don’t need to modify to make it fit properly? Now that I got this muffler here at the house. It’s heavy as hell and I’m thinking I should return and find a lighter option. Any suggestions?

Also, the two muffler straps for these exhaust. Where do they secure the muffler? I removed the back part of the engine tin so I could slide them into a position that looked proper..but clearly this is not correct.

[john walker's workshop]

You have to push and pry sometimes to get the bolt holes to line up. Normal. Obviously, the straps don't go over the rear tin.

[RarlyL8]

Backdating the exhaust to headers also requires use of the pre-1980 muffler bracket. That is what the straps will go around. Measurement of OE Porsche header flanges is about 22-3/4" on center. Most likely the muffler is fine and it's the new SSI's that are off. The original SSI's made in the USA were spot on every time, not any more. Also if you're looking for weight savings our stainless Sport mufflers weigh about 1/2 that of Dansk. The Street and Active Exhaust versions are a bit heaver than our Sport version.

[Jeff Higgins]

Those outlets won't clear your valance either.

[Gideon911]

John Walker- you don’t think I need a pre 1980 muffler bracket like RarlyL8 says?

Brian- thanks that’s helpful. What does the bracket attach to?

Jeff- I’ve got a FG rear bumper I’m going to cut so that’s not an issue. I’m aware it wouldn’t clear the stock valance. Thanks for the comment though.

[john walker's workshop]

Yes you do.

[mb911]

The correct way to install an exhaust system (if able to loosen the exhaust to head nuts) is to have both the header/heat exchangers loose and fit the muffler into position and tighten everything as a system. This is how it is done in aviation and translates to Porsche air cooled correctly.

The measurements Brain references are just that references. I have seen deflection of as much as 3/4" with oem stuff. When I designed the m&k muffler prior to Brian's ownership I took and average of as many oem systems I could. Bought ssi's, and the Dansk heat exchangers prior to them being one and the same along with Original heat exchangers and found them all over the place.

[Cairo94507]

MB911 is the exhaust Guru. He makes beautiful, perfect exhaust systems of the highest quality and they fit perfectly. I have his SS heat exchangers and muffler on my car which has an '87 3.2 and absolutely love them. Aside from that his mufflers are much lighter than stock. I have 2 of them, a "quiet" one and one that is a "bit louder". I run the louder one and it sounds glorious. I run the 2 in 1 out on my '71 914-6.

[Tony V]

Got a nice lightweight option for http://forums.pelicanparts.com/porsche-911-used-parts-sale-wanted/1099840-m-k-2-3-out.html

[LUFTKUL]

I've had to loosen the SSIs at the head exhaust ports just a tad then use a ratchet strap to pull the SSIs closer together at the muffler mating ports to get bolts on. I was nervous doing it, but it all worked out fine. That was with pre-Dansk SSIs and an M&K.

[Gideon911]

These are all useful comments thank you

MB911 thank you I’ll give this a shot tonight and see how it goes

Luftkul- that does sound a little sketchy lol mine looked off by about an inch and a half or so when one side was bolted up. That was before I got the pre 1980 bracket. I picked it up today from our host. Spoke to Dave at TRE and he thinks I’ll still need to make some modifications to the bracket to make it fit my car. Something about the cup in the 3.2 being different. I’m going to mock it up tonight and see if it will work by loosening the entire system..and maybe grabbing a ratchet strap :-///

[7783911]

Not hijacking but following...MB911 I sent you a PM

My 77 (with 83 sc engine and SSI) has some unknown sport exhaust (2 in 1 out) that may have a baffle within that is letting go. (a lot of noise on deceleration, no air leaks, fuel mixture good etc etc). This exhaust is quite loud as well so I would like to replace with something more sedate. I dont race it so if i lose a little HP as a result of changing I wont be concerned.

What do you recommend for quieter streetable exhaust

I appreciate the help

bob

[Gideon911]

What make is your exhaust?

Originally Posted by 7783911

Not hijacking but following...MB911 I sent you a PM

My 77 (with 83 sc engine and SSI) has some unknown sport exhaust (2 in 1 out) that may have a baffle within that is letting go. (a lot of noise on deceleration, no air leaks, fuel mixture good etc etc). This exhaust is quite loud as well so I would like to replace with something more sedate. I dont race it so if i lose a little HP as a result of changing I wont be concerned.

What do you recommend for quieter streetable exhaust

I appreciate the help

bob

[Jeff Alton]

We have had a couple of sets of SSI's recently with terrible muffler fit. Even tried multiple mufflers we had in the shop. To the level we had to cut and re weld tail pipes to clear the valance and bumper. QC has gone down the toilet currently....

Cheers

[7783911]

To be honest i dont know what make it is, neither did my shop...there arent any obvious marking. Its a sport model for sure 2 in 1 out, stainless steel

[shoooo32]

Every original steel heat exchanger I've had bolted up perfectly. The three sets of SSIs I've hung in the last two years have been 1/2" or greater off. Didn't matter if I was bolting up a stock sausage, Dansk sport, vintage Bursch or one of Ben's (which are basically artwork), the common denominator is the SSIs. As has already been said, their QC isn't anywhere close to what it was pre-Dansk.

[7783911]

I have SS SSIs that line up well with my exhaust (maybe a little coercion is needed). Before i would purchase a street exhaust i would find out center to center measurements in 2 in

[911pcars]

Engine rebuilding machining involving the crankcase, cylinders and/or cylinder heads could change the factory distance between the heat exchangers and thus the muffler inlet flanges, but not by + inch as reported. Sounds like the inlet tubes welding jig is "off".

I prefer not assembling pieces of anything in tension. Could result in structural cracks or failure some miles down the road. Perhaps some judicious heating and/or other metal massaging could encourage the parts to meet in closer harmony, maybe even heating parts after yanking the pieces together with chains, rope, straps and come-alongs.

Sherwood

[Gideon911]

At this point, I may just put the stock exhaust back on the car. I’ve been working on getting this reseal finished and just get back on the road. I don’t think it’s worth it to go through all the hassle and potentially break something in the exchangers to make this fit. Now I understand the danger in every trying to remove ssi’s that have been on for years.

Might be returning or selling this dansk 2/2. It’s all mainly for looks and a slight change in sound. No performance gain at all as it’s the same weight

[RarlyL8]

If the engine is being re-sealed the SSI must come off. They are too small for your 3.2L engine anyway. Put a set of 1-5/8" performance headers and a lighter muffler if you want to take advantage of the performance gains. If not put the stock system back on. We've got an active exhaust system that fits the OE exchangers if you decide to go OE and want a bit more sound/performance.