Muffler installation took 8 days. Wasn't working on it all that time, of course, but it took 8 days. Probably not such for you guys, but in my life, the urgent often crowds out the important. But enough whining.
Finished bolting up the new muffler about 7 tonight, and we took Sophia out to a local barbecue joint. I could not be more pleased. The long, round truck muffler fits the space better than the stock muffler did. New one weighs about 15 pounds compared to close to a hundred (I'm guessing on both, but I'm not far off). Looks much better — only when the hatch is open, no change in outside appearance. It's a tiny bit louder, which I like, and best of all, the acceleration is dramatically improved. Maybe the stock muffler was partially plugged, and that's what caused it to blow a hole in the side. I'll be looking forward to seeing the effect on MPG.
I spent most of a day (spread over last Thursday and Friday) getting the old beast off. Can't begin to describe that frustration, so I won't try. I grew up in a muffler shop, and I know a little about exhaust work. Clipped all the bolts with a torch, except that one. You know, the one tucked back in the L/R corner. I realized at some point that this bolt had been installed before the rear cap went on. That made it make more sense, but it did not make it any easier. That one bolt took at least 5 hours and involved two different trips for hardware. I finally worried the head off with a Sawzall. The rest of the removal was no problem. Here are a few shots:
Sorry that most of my photos are autorotated 90 degrees left. I can't help it.
Bolt in the last photo is the one that took so long. Next shot is the beast finally lying on the ground.
Next shot is the roof hole where the original muffler tip exited, and two after that show the square hole I cut to aid the new installation:
Here is the first test fit of the new muffler. A little synthetic grease helped it slide all the way into place on the next fit:
I used the new muffler to mark a hole for additional clearance in the SS floor of this compartment:
If I had known that the local NAPA had this clamp on the shelf, I would have saved the time I spent removing the original in shape to reuse. Our NAPA changed hands about a year ago. The new management is much easier to work with, but I'm just getting back in the habit of stoping there.
Don't appear to have a shot of the new clamp in place.
My new upper mount bolts to the roof framing with those wonderful Gillig Tee nuts:
NAPA also had this lovely rubber isolator. It has 1/2" holes. I cut it in two to make the cushions in my new, upper mount:
Here are most of the new upper mount pieces wearing 4 coats of Duplicolor engine primer/paint:
The original tail pipe looked like this:
I cut off this much to use again:
Here is the new upper mount in place. Came out well, and yes, those are grade 8 bolts securing the cross bar:
New muffler as seen from the rear hatch:
And from the side access door. You can see the new clamp here:
With that door closed, the exterior look is exactly as before:
This job took more time than it should have — BUT — any future muffler replacement will be quick, easy and inexpensive.
I bought this muffler NIB on eBay for $70. Shipping was about 25 more. I have about $120 in this job, maybe $130 counting Sawzall blades. I didn't even bother asking Gillig what an original would have cost, but you can bet it would have been many times more than what I spent.
Now, if I can just find out when my class is racing behind Moondoggy's Diner....
Best to all,
Jim