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Date:         Mon, 15 Nov 2004 20:09:38 -0800
Reply-To:     "Andrew G. Martin" <agmartin@GIS.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         "Andrew G. Martin" <agmartin@GIS.NET>
Subject:      S&S muffler installation - anybody got photos?
Content-Type: text/plain; charset="iso-8859-1"

I installed a set of S&S headers and muffler on my 85 Westfalia with a stock 1.9 L engine. Everything fit well but the system came with a weird assortment of nuts and bolts, some useful some not. I had the transmission out (thanks Daryl) when I installed the exhaust so installation and fitment was easy. My engine seemed to run smoother with the new exhaust although slightly louder than stock at idle. Within the first couple of months I noticed that the muffler got louder and began to rattle from the inside. I spoke with and e-mailed the vendor that sold the system to me but never got any real response to my problem I had hoped that it might get replaced under warrantee but as I said, the vendor didn't respond. I waited patiently for two months then ordered a new S&S muffler from a different vendor. I have installed it exactly the same way I installed the first one. So far it is much quieter and does rattle like the old one did. Inspection of the old S&S muffler revealed cracks and exhaust leaks where the mounting tabs are welded to the muffler and cracks and leaks around the inlet flange on the Cat side.

As I said earlier, I installed the new S&S muffler exactly the same as the old one. To secure the muffler to the rest of system, I used the stud tabs on the rear header flanges to attach 2 stock exhaust brace/bars that I modified to fit. I also added a couple of exhaust pipe clamps and a piece of steel bar stock to secure the pipe before the Cat to the header pipe. I don't see how it would fit any other way. Everything is tight and the entire system moves together with the engine, as it should. But I'm still not satisfied and I fear the new one will fail as the old one did. I know the new vendor will stand behind what they sell but if I have somehow I installed this thing incorrectly I want to know sooner rather that louder (pun intended) because I'm down 160 bucks. I would appreciate it if another S&S exhaust system user could e-mail me some photos that show how they installed their system and braced their muffler. I will gladly send back photos of mine if wanted.

Thanks!

Andrew

Andrew G. Martin Gloucester MA agmartin@gis.net '85 Westfalia 165K


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