I’ve been busy mocking the exhaust system. Everything up to and including the catalytic converter will be 321 stainless steel and everything after will be titanium. Titanium will minimize the weight behind the rear axle and it should provide a slightly different sound… not to mention look cool. Since I’ll have exhaust cutouts I’d like the primary exhaust to be relatively quiet. The plan is to run two mufflers on each side:
Round muffler, 3.5” inlet/outlet, 10” long body (12” total length) with 4.6” diameter
Hard 180-degree, fabricated from two mandrel-bent hard 90’s
Oval muffler; 3.5” inlet/outlet, 10” long body (12” total length) with 6” x 9” oval profile
The challenge is figuring out if it they will fit and if so, how. I bought some 2” pink insulation foam at Home Depot and cut the muffler profiles on a bandsaw. 3-1/2” deck screws were used to attach the pieces and three pieces of 1/4” plywood and two pieces of scrap aluminum right angle were used to mock the 180-degree tube and to space the mufflers apart.
After some fiddling the best fit was with the oval at the bottom with its center offset by several inches from the round muffler and rotated such that it was parallel to the ground. I was already planning on stretching the tail to match the curvature of the tail lights and it looks like I might need to stretch it a few inches further to get the oval muffler to fit. In addition, I’ll need to create a bucket for the tail light, wrap it with heat shield and create a thin vent above the tail light to let heat escape.
The next step is to figure out how to connect the tube from cat to the mufflers and the tube from the mufflers to the tips. This will be accomplished with a bunch of pie cuts.