Vic_S

I've seen several threads where the final muffler has failed - especially where there has been a primary bypass / cup pipe.

Well, I have now joined that group!

But I haven't seen the results of any successful repairs...

I guess the simplest thing to do is weld up the cracks & then maybe weld a patch on top. Has anyone done this / has it worked?

martin964

Hello Vic,
mine went similarly (I have a cup pipe). I bought a second hand silencer from douglas valley, and my split silencer is currently with a friend for welding up. I think several other guys on here have had this done with good results

cheers

martin

nugatory1

My secondary muffler also split. I noticed it as I was putting on a primary bypass pipe, so it split with a completely stock exhaust system. I just had it welded at the local muffler shop, but mine had only split along the seam. Not sure how long it will last. Muffler guy suggested I find a new one ($$). He was also surprised by how thin the metal was.

Vic_S

Thanks for the comments guys, it seems a lot of us are suffering this.
...and Yes, I agree, it is thin metal!

Laker

Would if not be more cost effective to replace the final with a G pipe then pull the cup pipe and reinstall the original muffler? Sound should be similar. Redline HP gains would be replaced by low end torque. Just a thought.

Vic_S

Yep, I would have done that, but unfortunately I sold the Primary Muffler some time ago

tbennett017

I have a spare primary if you'd like it, but it's in the US...

Also I'd disagree with Laker, (respectfully) but the sounds are very different from the two setups. I agree that the torque increase is true, but I prefer the cup pipe setup for the different sound.

911Jetta

+1. And will buy another 2ndary if this one cracks too. Love the sound of the primary bypass set up.

Here's how my cracked...

Laker

TB, Jetta, I stand corrected.... thank you

fstockcarrera

How is the sound different? I'm going to put the primary muffler back on an run a G pipe in an effort to get the sound to 88 db for Lime Rock Park. I'll run both mufflers if I have to. BTW 90db measured at the track with the cup pipe and secondary muffler.

911Jetta

A secondary bypass has a more gruff, woof-woof sound (sorry I know that's a horrible description...check U-toob for videos). Sounds more like a Subaru flat six. That said, it still sounds good...

I'll let the track guys give you the final answer, but based on reading past threads and my parking lot observations, I think bypassing the primary (using a G-pipe) is louder.

Andy Roe

Yep, the G-pipe is louder. I've tried both and the primary by-pass is a much nicer sound in my opinion. Each to their own though!

(Hi Udo! You not coming to Paris this year then?!)

Vic_S

And here is the repaired muffler...

Tb2johm

Hi! What material was it made of? Stainless?

Vic_S

Yes it was