Rebuilding the DF exhaust system

Rttoys

Rttoys

Goblin Guru
I have had a rattle for some time now inside my muffler. I figure the baffles have come apart at some point and rattling around now. Also at our last few autocross’s they have been doing db checks and I’m over the limit (104db, can’t be higher than 100db). I figure it’s time to see what’s going on inside the muffler.

these look to be similar to a flowmaster, not using baffles, just using chambers to muffle and tune sound. Peaking inside I could see the baffles but couldn’t get them out. One of my co-workers always says “it’s broke, right? Can’t get any more broke.” So I cut the end off. Sure enough, the baffles were detached and the exhaust is basically wide open. Since there’s no good way to weld them back, I bent and pulled the baffles out and decided to see if a flowmaster would match up.

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luckily a flowmaster does match. A 40 and 44 series are direct matches, so I chose a 44 series to keep the noise down. Part # 942546
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After a bit of measuring, I cut the original muffler and flowmaster to match.



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Welded the new muffler in and check for leaks using my evap smoke tester.
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Painted it up and installed on the car
before:
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After
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the sound is quieter and has a much better tine now. Next autocross I’ll see what the db’s are.
 
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PyroGuy923

PyroGuy923

Well-Known Member
Did you get a new flange? I've been debating building one from the turbo but am having a hard time finding the proper flange. May just get an aftermarket downpipe and go from there.
 
Rttoys

Rttoys

Goblin Guru
Robinjo

Robinjo

Goblin Guru
Rttoys said:
For the muffler replacement it was just a cut and splice of the muffler, to get me by for a while. The new one I’m going to build I did buy a new flange. Got it from zzp.
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I just bought the flange from DF. I like ZZP but would rather give my monies to the Doyle's. Since they have been so good to the community I just buy from them unless I have to outsource. I've also been toying with the idea of a new exhaust setup and it's nice to know a Flow Master will fit in there. I'm curious to see what the ZZP box holds. The sound from the stock DF exhaust setup is a little underwhelming (in my opinion).
 
Rttoys

Rttoys

Goblin Guru
It’s nothing special actually. It’ll be like the one I built out of a motorcycle exhaust, basically straight. I bought a zzp resonator and sound reducer, so buying the flange from them was convenient, plus it’s all stainless. I’ll take a pic of the mock up today or tomorrow.
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Robinjo

Robinjo

Goblin Guru
I was thinking something similar. A burnt tip unit normally on an import. Kind of pointed up in the air….
 
Rttoys

Rttoys

Goblin Guru
This will be part 2. Zzp quiet resonator with sound reducer, welded to a flange. I’m going to cut down the inlet to make it more compact.
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jirwin

jirwin

Goblin Guru
Haha I'm doing the same thing this weekend since my Vibrant setup was waaay too loud. I didnt get the sound reducer though. Hopefully this quiets it down enough, but after seeing it, I doubt it. The way they word it they make it sound like its not straight thru, but apparently it is. Maybe I'll try to do Vibrant and ZZP both.
 
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