Wayne's Trick For Installing Muffler Straps...
 

After trial and error on this one, I came up with a very good (and safer) way to install the muffler straps.

Problem: The straps are round, the muffler is not. You don't have enough force in your hand to squeeze them together in order to thread the *small* bolt through. Pliers and vise grips will sometimes work, but they will also slip, scratch your muffler, and will bend the straps so that you can't get the bolt through.

Solution:

Get a longer bolt with the same thread pitch:

http://forums.pelicanparts.com/uploads/bolt-1.JPG

Then thread that bolt into the muffler strap. You can simply use the longer bolt, but this one isn't stainless, and looks dopey when it's hanging out the back. Tighten down the muffler strap to it's desired level:

http://forums.pelicanparts.com/uploads/bolt-2.JPG

Then take a zip-tie and carefully wrap it around the two straps:

http://forums.pelicanparts.com/uploads/bolt-3.jpg

Now, remove the longer bolt. The zip tie should hold the muffler strap in place:

http://forums.pelicanparts.com/uploads/bolt-4.JPG

Now, you should be able to insert the shorter, stainless steel bolt with no problem:

http://forums.pelicanparts.com/uploads/bolt-5.JPG

Note, this is the method that I used *after* I injured my hand - not the one that I was trying. I was trying to simply use the zip tie to tighten the strap together (by pulling on it really tightly), when it broke. Note - you shouldn't try this - use the larger bolt to compress the strap together...

-Wayne

Once when I was a kid, I sat on an ant hill. Not on purpose. Red and hill. Well, moments later I was running home screaming. After removing the ants from my body, I went to the encyclopedia and pulled the K volume and the A volume. When asked what I was researching, I replied "I want to learn how to Kill Ants." Wayne, I imagine I've probably lost you again (I didn't attend MIT), but my mistakes stick to my ribs too. I guess you could say I'm focused, at times.

And on a thinly related note...I just thought of a great way to write off an engine rebuild. WRITE A BOOK.

nice band-aid!

I'll say it again, these books are just not worth it by themselves...

-Wayne

Oh cable ties: the bailing wire of the 21st century!:D I also a have roll of soft steel wire in my garage for the more traditional "fix" along with a dozen sizes of cable ties in white and black. Jim

I have a big bucks safety wire tool and a cheap Harbor Freight safety wire tool that cost about $8........Ron

Zip ties are nice, and I carry them. Some are over 2 feet long. But zip ties won't help you when you really need baling wire.

Another of life's eternal truths from Super - ROTFL, because it is SOOOO true.

There are those that know, and those that will learn soon enough.......

NICE
 

I must say I like those pics Wayne. Who is the bearer of that powerplant?

Coool Wayne, but what happened to duct tape and a really big hammer?

That's my engine - probably going to be a display motor for a while...

-Wayne

My friend the auto tech. likes to make fun of his trade. His self-deprecating repair mantra goes like this:

Hammer to shape
File to fit
Paint to match

Wayne, maybe you could add these words of wisdom at the end of the book; perhaps a chapter entitled, "When All Else Fails." :)

My feeble attempt at a little levity,
Sherwood Lee
http://members.rennlist.org/911pcars

I've found that a Testor's model paint pen is great for touching up inevitable scratches in the paint that will occur. Especially during re-insertion into the car!

-Wayne

This works!
 

A bump to an 8-year-old + thread but just wanted to say this method works! I used it over this weekend to install new straps on my old muffler. I removed the muffler - a standard factory Bischoff 2-in, 1-out - to repaint and the original straps were pretty twisted; I didn't trust their potential longevity.

Thanks, Wayne! SmileWavy

Ed

True words, but they worked superbly in this application, no? :D

Wayne, two things I learned from reading this thread. #1, We all have the same problems and #2, Testors are Still In business?? I used them back in the 50's on my U Control Airplanes I flew. I think it was not Fuel Proof so I preferred Comet (At least that is what I think the other name was:) )

In 2002 when this thread was started I was just researching to buy the 911 I bought a year later. Since then, Wayne has moved on to Boxsters, 996's and to the mighty 959, yet I'm still sitting here with the same old 911. I'm in the wrong business!

Great tip. I always hate scratching up my hands trying to hold those muffler straps together for the 'not long enough' bolt.

Is this motor now in use?

Great tip. I struggled with the straps a couple times and this is an easy solution.

i just threaded zip ties thru the bolt holes till they were close to the gap the bolts would take up... then did the outside zip tie trick wayne used and cut the first zips... installed bolts and drove a little to let the heat do its trick... snugged down the bolts... wow :eek: the zip ties were still there after a few weeks later... i thought it got hot back there