Author Topic: New Muffler for the Volvo  (Read 8072 times)

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« on: August 04, 2013, 07:45:45 PM »

Michael Yount

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New Muffler for the Volvo
« on: August 04, 2013, 07:45:45 PM »
Sorry about the loss of pics on the suspension thread.  I finally organized my photobucket account into subject libraries without copying them into the new files -- not realizing that would screw up all the links!  Oh well....
The 10 year old replica Boss 429 muffler on the 5.0L Volvo is getting louder.  Packing wearing out -- and, let\'s face it, it never flowed very well.  So I wanted something to replace it with that would be relatively quiet and flow better.  Looked for months for hi HP OEM used mufflers that might work but could not find anything that wasn\'t too big.  That\'s how they manage lots of HP without much loss AND keep them quiet - they make the cases huge. So I bought a couple of 2012 used 5.0L Mustang mufflers thinking I could put them ahead of the rear axle where most muscle car mufflers reside.  Alas - too big for that (15.5\"L x 6.25\" H x 12\" W).  So, I\'m converting them into a single transverse unit to go at the back -- similar to the Boss 429 muffler I\'m removing.

Started with these...



Cut the ins/outs off...



Want to end up with something that\'s configured like this, but more compact...inlets pointing to the front of the car; outlets side by side right in the middle under the rear bumper...



Found this image on the web where someone did me the favor of showing me what the inside looked like.  



Now I knew I could fit a 90 degree ell inside the muffler to turn the outlet out the side of the case like so...



You can see what has to be removed to make room for the ell...



Fast forward -- several cutoff wheels and the versa saw later...voila!





And then some detailed work inserting the Dremel/cutoff wheel THROUGH the original outlet to remove about an inch of the baffled inner pipe (2.75\" inside the 3\" surrounded by packing) so the elbow could slide in....and you end up with this!  Ready to weld the ells in.  Then I\'ll close up with some new aluminized sheet with a hole for the outlet.  Want to use new sheet because the old casing was double wall and came out in two pieces that separated when removed -- that\'s because the muffler is a stamped unit.  And because a slightly bigger piece will let me do a lap weld where there\'s lots of metal rather than a butt weld with light gauge metal.  Once it\'s all closed up I\'ll weld the two mufflers together all the way around the perimeter to seal and create a single unit.  And I\'m leaving the original outlets open to each other so that the sound/sound waves from both sides will combine/mix inside.





As a reminder, it will go in place of this...

'82 Volvo 242; '10 Cayman S; '15 Fit

«Reply #1 on: August 05, 2013, 09:22:22 AM »

02JEEPX

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New Muffler for the Volvo
« Reply #1 on: August 05, 2013, 09:22:22 AM »
Can\'t wait to see the finished product!
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«Reply #2 on: August 05, 2013, 01:28:03 PM »

Hemicota

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Re:Re: New Muffler for the Volvo
« Reply #2 on: August 05, 2013, 01:28:03 PM »
I can\'t wait to hear the final product!

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«Reply #3 on: August 05, 2013, 01:52:14 PM »

Michael Yount

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Re:Re: New Muffler for the Volvo
« Reply #3 on: August 05, 2013, 01:52:14 PM »
LOL - I can\'t wait to NOT hear it.....
'82 Volvo 242; '10 Cayman S; '15 Fit

«Reply #4 on: August 05, 2013, 04:22:04 PM »

02JEEPX

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Re:Re: New Muffler for the Volvo
« Reply #4 on: August 05, 2013, 04:22:04 PM »
Where is the cutout for the straight exhaust? Surely you gonna want to hear it every now and then.............
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«Reply #5 on: August 05, 2013, 04:23:03 PM »

02JEEPX

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Re:Re: New Muffler for the Volvo
« Reply #5 on: August 05, 2013, 04:23:03 PM »
Rear diffuser coming soon?
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«Reply #6 on: August 05, 2013, 05:50:19 PM »

Michael Yount

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New Muffler for the Volvo
« Reply #6 on: August 05, 2013, 05:50:19 PM »
Cut-outs?  I\'ve heard mild pushrod V8\'s with open exhaust.  Nobody wants to hear it again.  Diffuser -- LOL!
'82 Volvo 242; '10 Cayman S; '15 Fit

«Reply #7 on: August 06, 2013, 06:09:54 PM »

Michael Yount

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New Muffler for the Volvo
« Reply #7 on: August 06, 2013, 06:09:54 PM »
I welded the ells into place.  And I think I found my exhaust tips.  The long stainless pieces that I cut off the mufflers are just going to be too long to work on mine - even shortened they would stick way too far out the back.  So I got to looking at the pieces of pipe I cut out of the inside of the muffler -- pictured below.



They are a 2.75\" x 3.00\" transition piece with the 2.75\" louvered piece nested inside with the fiberglass packing between the two.  So I carefully cut the louvered piece lengthwise and removed it along with the packing.  This left the 2.75\" x 3\" piece -- which looks, based on initial measurements, to be the right length for my \'tailpipes\' - 3.5\".  And it would result in twin 3\" side by side outlets at the back.  I\'ll tack them and once the muffler is fitted if they\'re not long enough, we\'ll simply add more 3\" to the proper length.



'82 Volvo 242; '10 Cayman S; '15 Fit

«Reply #8 on: August 07, 2013, 08:15:47 AM »

02JEEPX

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New Muffler for the Volvo
« Reply #8 on: August 07, 2013, 08:15:47 AM »
So you are adding resonators? Those gonna polish up?
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«Reply #9 on: August 07, 2013, 08:45:28 AM »

Michael Yount

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New Muffler for the Volvo
« Reply #9 on: August 07, 2013, 08:45:28 AM »
So - you can\'t just look at the pictures - you gotta read too!  \"So I carefully cut the louvered piece lengthwise and removed it along with the packing. This left the 2.75\" x 3\" piece -- which looks, based on initial measurements, to be the right length for my \'tailpipes\' - 3.5\". And it would result in twin 3\" side by side outlets at the back. I\'ll tack them and once the muffler is fitted if they\'re not long enough, we\'ll simply add more 3\" to the proper length.\"  The biggest piece of that \'resonator\' is inside the muffler.  I removed the louvered piece/packing leaving just the 2.75\"x3.00\" piece of pipe.  

As for polish - there\'s no chrome or polished pieces on the car anywhere.  The tips will be black as all exhaust systems should be.  ;)
'82 Volvo 242; '10 Cayman S; '15 Fit

«Reply #10 on: August 07, 2013, 09:29:28 AM »

02JEEPX

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New Muffler for the Volvo
« Reply #10 on: August 07, 2013, 09:29:28 AM »
LOL You should have pic\'d it! You know noone reads this stuff. The internet is all about pics and vids! GROW UP I just wanted to imitate the response you got on the other forum.....but you didn\'t highlight mine :(
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«Reply #11 on: August 07, 2013, 12:20:19 PM »

Michael Yount

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New Muffler for the Volvo
« Reply #11 on: August 07, 2013, 12:20:19 PM »
Actually, there are two \'pics\' of it....but I\'ll follow up with one looking in the business end for my unimaginative illiterate 30-something friends   LOL
'82 Volvo 242; '10 Cayman S; '15 Fit

«Reply #12 on: August 07, 2013, 01:01:19 PM »

02JEEPX

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New Muffler for the Volvo
« Reply #12 on: August 07, 2013, 01:01:19 PM »
Thanks for thinking I\'m thirty something :)
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«Reply #13 on: August 07, 2013, 03:59:36 PM »

Michael Yount

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New Muffler for the Volvo
« Reply #13 on: August 07, 2013, 03:59:36 PM »
I didn\'t want to bust you up too bad --- old and illiterate!  ;)  Here ya go -- this is all dressed out so that everything is even, gaps are less than 1/32\" and everything is level/ready to weld.  These are the 3\" tips that will just barely poke through the valance under the bumper.

'82 Volvo 242; '10 Cayman S; '15 Fit

«Reply #14 on: August 07, 2013, 05:32:14 PM »

02JEEPX

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New Muffler for the Volvo
« Reply #14 on: August 07, 2013, 05:32:14 PM »
LOL, NICE. Looking good so far.
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