DIY muffler fit

[witewalzs]

Hadn't planned on doing this until I modded the front half of the exhaust system first but , seeing as I was going to take the original muffler off to ease fitment of my custom towbar ,I thought I might as well do the Berklee (BSO655)mod while I'm under the car. Couple of pointers for anyone wanting to have a go.The biggest one ,which may have been mentioned somewhere in this forum but I didn't pickup on ,is that the exhaust pipe narrows dramatically (60to50mm)just before the last flange in front of the box. So simply cutting the old box off and welding the pipe back onto the new one(as i thought) aint gonna work as the Berklee is much bigger , you will need to cut just before the flange were the pipe is still 60mm and then use a 63mm(2.5inch) 45 degree mandrel bend to complete the union.The 63mm fits nicely over the 380 pipe and inside the Berklee for ease of welding. Firstly, transfer the brackets from the old to the new taking into account the slight difference in box size by measuring there placement from the center of the inlet/outlet holes as this is the common point between the two boxs.Hang box under car and play with the 45 degree pipe to get the "angle of the dangle" just right before welding .Remove the factory oval tip by grinding or drilling the spot welds on the top and bottom then pull the outer off the inner.Cut the inner off and then do the reverse to refit Do this bit after the box is on the car to make sure you get it straight.