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Reply to "Thunder Ranch build thread"

@DannyP posted:

I hear that!

I bought a 3" mild steel exhaust extension from Jeg's, and made a one bolt clamp on it. Inside, I welded a Vortex cone insert. Zero back pressure increase, but takes the edge off the exhaust while idling, but especially during cruise. Plus keeps the soot off the car!

My goal was twofold: dampen the note a bit, and de-soot.

Although not period correct, I wanted to go with the 911R exhaust look. I bought the "cookie cutter" inserts from GT Racing and a 2"-4" megaphone from Speedway, and a length of perforated pipe for a baffle from eBay. 

I dug deep into my memory and did some math for the right lengths. From memory, to make the megaphone fit in my pipe, I cut 3" off the small end and 1" off the big end, just where the cookie cutter ended up. (A huge stroke of luck: the angle on the CC blades matched the angle of the megaphone almost exactly. I had to do minimal grinding to get a perfect fit.) 

Then I had a welder friend put it all together. 

Since it hit my license plate when I raise my clamshell, it had to be removable, so I had the welder weld some half-washers to the pipe and cookie cutter and I use springs to hold it in, like a motorcycle slip on. 

Finally, I had it ceramic coated to match the exhaust. In the end, I also cut off 1.5"-2" of the tail pipe to get the proper length. 

 

Prior to getting coated:

image

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Last edited by dlearl476
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