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Aftermarket muffler advice needed

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Old Nov 29, 2004 | 07:08 PM
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Question Aftermarket muffler advice needed

My 1980 is due for a new muffler. I'm looking for an inexpensive/cost effective alternative to factory parts. Not necessarily interested in spending more $$$ for added performance, just want to make sure I pass smog. Any suggestions would be much appreciated!
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Old Nov 29, 2004 | 07:20 PM
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I know alot of guys/gals here are running Borla mufflers, a little $$$ but well worth it.
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Old Nov 29, 2004 | 07:53 PM
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The complete Borla exhaust system I have in stock for $495. That is all stainless steel includes the intermediate section with resonator rear pipe and rear muffler . It is a simple bolt on installation. Any number of generic mufflers can be fitted none have any effect on emissions/smog checks
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Old Nov 29, 2004 | 08:37 PM
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I replaced the big tub muffler with a 40 series flowmaster - parts and labor = 175.00

YMMV
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Old Nov 29, 2004 | 08:49 PM
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Originally Posted by Jim bailey - 928 International
The complete Borla exhaust system I have in stock for $495. That is all stainless steel includes the intermediate section with resonator rear pipe and rear muffler . It is a simple bolt on installation. Any number of generic mufflers can be fitted none have any effect on emissions/smog checks
It is a simple bolt-on installation... unless you have the giant early battery box I'm referring to Borla P/N 14276, the cat-back system. Also, the front flange would not accept the sealing donut, I had to cut a gasket for it.

Jim, if you are offering a different Borla P/N then I'll retract what I've said since I only have experience with the above-mentioned Borla part.
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Old Nov 29, 2004 | 11:06 PM
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I have the Borla system and it is WELL worth the money! Talk about your high performance European sounding exhaust! This system screams HI-PO at WOT
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Old Nov 29, 2004 | 11:59 PM
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Originally Posted by 928ntslow
I have the Borla system and it is WELL worth the money! Talk about your high performance European sounding exhaust! This system screams HI-PO at WOT
Oh, don't get me wrong... I love mine, and feel that it was definitely worth the money... plus the money I paid to have it "adjusted" to fit the OB.

I just want to clarify that the Borla setup needs to be "tweaked" to fit certain cars, unless you don't mind having it cocked at an odd angle and pressing hard against the battery box.. And unless you can weld stainless it's not a DIY job beyond getting the resonator on. YMMV.
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Old Nov 30, 2004 | 01:02 AM
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Hmmm...mine was an easy bolt on with no mods...no interference. I guess the pre 80 cars have something that is different. What has to be welded?
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Old Nov 30, 2004 | 01:11 AM
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I think the Borla is the best cat back sys for the 16v. Nice sound, doesn't overpower the radio at hi way speed, and it's stainless steel. My ANSA rusted out after 10 years. 500 is a nice price.
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Old Nov 30, 2004 | 02:22 AM
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Originally Posted by 928ntslow
Hmmm...mine was an easy bolt on with no mods...no interference. I guess the pre 80 cars have something that is different. What has to be welded?
Actually he cut off the pipe that was welded to the rear muffler, mandrel-bent up a new piece, and welded it to the muffler. The issue was making it fit in that area with the monster-sized battery box. In the pic below, you can see that the pipe sits just above a rib stamped into the battery box bracket.

Out-of-the-box, the pipe wanted to sit an inch or so lower, going right through the space occupied by that rib. There was no way to fit it in around the battery box without the tips coming out at an angle that looked stupid... IMHO. They were off-center in the arch, pointing down about 20° and forward a bit... on top of that, one tip was noticeably closer to the ground due to the way I had to twist the muffler. It's hard to describe... I should have taken a pic. I'm sure it fits fine in the later cars with the smaller battery box.

While he was at it, I had him weld a fitting for the factory hanger that mounts to the battery box, and add a triangulated brace for the tips(2nd & 3rd pics). Again, I am VERY happy with it now; form, function and BWAAAHHHH!





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Old Nov 30, 2004 | 09:57 AM
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The Borla sure looks nice as well, stainless steel so it should last as long as a 928 does too. You might want to consider a muffler bypass, mine is from 928intl & sounds great!
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Old Nov 30, 2004 | 12:37 PM
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Brian, they aren't available for the early cars...
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Old Nov 30, 2004 | 12:41 PM
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Dave who said the Borla fits the 1978 ?? Certainly not ME ! The car in question is a 1980. Borla and others THINK it fits the 1978 but it does NOT! The 1978 used the weight of the battery and box bolted to the transmission differential to off set vibrations in the drive line. By 1979 they determined it was not necessary and simply welded a battery box to the cargo area floor eliminating the brackets. The Borla fits 1979-1984 USA cars with single exhaust does not fit the Euro S two pipe. Borla continues to make this system ONLY because we order in sufficient quantities that they agreed to make a run once in a while. About four years ago they had decided that they would kill this part just as they had the two pipe system and the S-4 system due to low demand. Brian glad you like the RMB it works very well for the late 86-95 BUT the early single pipe system if you remove the rear muffler there is not enough muffling from the small single resonator and it is too loud for most people's taste. As our store indicates it fits the 79-84 cars very nicely and sounds great ! weighs less and is stainless steel.
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Old Nov 30, 2004 | 01:06 PM
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No Jim, I bought mine elsewhere. I never heard you say it would fit the 78, but the folks I bought it from DID say so. Didn't mean to hijack...
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Old Nov 30, 2004 | 01:24 PM
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No doubt Borla makes a nice product. I toured their facility about 4 yrs ago as a business banker when they were shopping around for credit lines. Very interesting place. I'd love to go with a Borla set-up but alas, the car will be for sale soon. I'm trying to replace the muffler(s) - are there 2? The thing is popping from back pressure, rattling, etc. it's toast. My mechanic will have a looksy in the next week. I just got a SICK 993 and unfortunately can't afford to keep both cars. I will post photos when she's ready for sale. I think the overall condition of the car, the genuine 18inch turbo twists with new tires, stereo, etc will definately make it an attractive car. The only non-factory parts on this car are the Eibach springs, everything else is Porsche parts. This would be the first time I didn't go with a factory part so I want it to be a decent muffler but maybe a flowmaster might be just what the doctor ordered. The new owner can switch it out if they don't like it, I just need to pass smog for to sell. Whats the story on the flowmaster quality? Any pics?
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