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keithiopian · Posted: Thu Jun 15, 2006 7:42 am Post subject: sheared exhaust

so the people i got my 924 from put an aftermarket exhaust on it. which is all well and good. however, that was some 30 years ago around, and i'm driving down the road the other day, hit a bump, and slowly my car starts getting louder and louder. "sweet" i say, "now all the honies will really dig me!" by which i mean i took a look under my car and saw that the 4-into-1 had almost completely sheared at the weld by the connection flange to the cat.

Which leads me to the question:

1) anyone know any good repair places in los angeles for 924's, and or someone who could possibly (although i doubt it) reweld it with any sort of structural integrity?

2) does anyone know of any california legal aftermarket exhausts to put on 924's?

thanks!

-keith

Joes924Racer · Posted: Thu Jun 15, 2006 9:51 am Post subject:

LOUD huh sounds terrible. You can buy a after market performance header from mds its about 200 bucks from there go to a shop and see what they'll charge to fabricate the rest up. Try Midas

_________________
1979 porsche 924 Na
1980 porsche Turbo 931GT Replica
Have u ever driven a turbo.

gohim · Joined: 02 Nov 2002 Posts: 4459 Location: Rialto, CA

The stock exhaust was a cast iron exhaust manifold going into a tubing 2 into 1 collector pipe, connected to a cat adapter pipe, connected to the cat, which was bolted to what is called the "final muffler" which consists of the center muffler a crossover pipe and the rear resonator with tailpipe.

Exactly what was installed as a aftermaket exhaust system on your car? In CA, you are not going to pass the visual emissions equipment if you remove the cat, or if you change to headers, unless the headers are CA approved, and you have the exemption number to show to the smog tech.

If the previous owner installed headers and removed the original exhaust manifold and collector pipe, are the header a single piece, or a short header and a collector? Where did the collector break? If the headers are the two piece style, you could try finding an exhust shop that is willing to use your broken collector as a pattern to fabricate a replacement header.

On my 81, the entire exhaust system was trashed by the P.O. who apparently liked to scrap the exhaust on things. Eventually I had to replace everything from the tailpipe forward except for the exhaust manifold and the cat adapter pipe, because of physical damage. The 2 into 1 collector pipe broke just forward of the rear flange, infront of the mounting bracket. I ended up buying a good used one from Parts Heaven in Northern CA.

Currently I am using a ANSA OEM Style final muffler and a replacement cat that I bought from a Porsche Dealer ($10 on sale) on my 924. I bought a 944 final muffler, and a picked up a used 944 exhaust (from the exhaust manifold back, including the cat) in anticipation of converting to the 944 exhaust (documented 8-10 hp gain, and a simple bolt on after the 944 collector pipe is cut and flanged to bolt to the 924 collector). I didn't do the 944 conversion because I bought a 924S, and am planning on selling the 924 someday after I get an engine built for the 924S.

If you are planning on keeping your car, and want the power boost for practically no more that you are going to pay to replace the 924 exhaust, I recommend the 944 exhaust conversion. The 944 uses a collector pipe that bolts to the exhaust manifold and is welded to the cat. This, and the final muffler (everything from the cat back) comprises the 944 exhaust system. If you can find a used, complete exhaust system (from the tail of the exhaust manifold back) in good condition for a decent price, buy it. If you can't get the whole exhaust system, get the collector/cat assembly, and buy a new ANSA 944/924S Final muffler. The price of the ASNA 944 final muffler should be less than $200, including shipping. For a long time several companies were advertising them for $150.

I actually bought a pile (8 or 9) of brand-new 924, 944. 851 final muffler assemblies (Porsche OEM and aftermarket) from an aftermarket parts company at a local auto parts swapmeet for about $30-$40 and resold the ones I didn't need on eBay for between $80 and $125.

keithiopian · Posted: Thu Jun 15, 2006 3:07 pm Post subject:

my setup is as such: 4 into 1 header, aftermarket, not necessarily all that legal (shhhh, still got it to pass visual...), straight into the cat, into the final muffler. it sheared right where the 4 into 1 meets the cat. [/i]

Vince Ponz · Joined: 02 Nov 2002 Posts: 3581 Location: Florida

30 years on a exhaust and you are complaining? Buy a new one you cheapskate. Why??

The rest of it is rotting and you will soon have more holes in it. I used Stahl headers.....nice and sturdy for years. York, PA.
_________________
"Never let them see you sweat"
77.5 924 modified track car
79 931 Euro stock
88 924S SE
87 911 Targa stock

keithiopian · Posted: Fri Jun 16, 2006 1:33 am Post subject:

woh now, if you check the original post i never did any complainin, just statin the facts, and i was more than willing to buy a new aftermarket exhuast. for now, i took it down the block and had him toss a weld on there for 15 bucks, but i'm still lookin for new headers.

as for the smog legal part...well it seems there's only one header in california (aftermarket) that is smog legal, and thats for an engine conversion only. seems like i'll have to continue goin it on the sly...