How to install a Glasspack in Place of Your Cat
- Glasspack muffler - $15 to $25
- 2-4 muffler clamps
- Piece of 2 1/4" outer diameter pipe that is about 4 inches long
- Piece of pipe that's 2 1/4" ID on one end and 2 1/4" OD on the other end, about 4 inches long
- Clothes hangers, romex, etc
- 14 mm wrench or 13 mm wrench depending on muffler clamp type, and a 15 mm wrench for the hanger
- Hack saw, sawzall, or muffler cutter
How To Do It
Cut the cat as shown in the below picture. Be sure to cut out a length slightly longer than the length of the glasspack muffler you will be replacing it with. You will have to leave enough pipe on the end closest to the engine to put the 2 1/4" dia. 4" long pipe into. Note: pipe diameters may vary between 2" and 2 1/4" depending on the year of your car.
Once you cut the pipe, look inside the piping closest to the muffler...there should be a piece of the pipe inside that was inserted there back when it was first made. Remove this with pliers and file the edges of the piping smooth.
Insert the 2 1/4" pipe into the piping closest to the motor. Hold onto the piping and securely tap it into the pipe. It MUST be inserted at least 3/4" to properly seal and support the muffler!
Place the muffler over the protruding pipe you just inserted and push it on until the muffler's end touches the piping from the engine. Place a cinder block under the muffler to hold it up until u make the hangers, so as to take strain off of the pipe.
If you look on the heat shield that is attached to the body, there are small holes drilled in it. You can use these in combination with either a piece of clothes hanger or stripped romex to hang the muffler. Simply push the muffler up into the cavity, thread the hanger through both holes, then secure it so it won't come out...then simply allow the muffler to rest on the new "hanger".
Now you're ready for the clamps. You will have to use 2 clamps on the front side of the muffler; 1 on the muffler, about a half inch back from the mouth, and one right on the end of the pipe coming out of the engine.
To connect the glasspack to the rest of the exhaust system, the you will need the piece of 2 1/4" ID on one end and 2 1/4" OD on the other end pipe. Place the larger end over the rear exhaust pipe, undo the hanger's 15mm bolt and the swing the pipe into the glasspack muffler. If the hanger doesn't line back up, remove and shorten the pipe until it does. Then clamp both ends of the pipe, retighten the hanger nut, and voila! No cat, no bees.
The pipe can be welded, but I recommend against this. If for some reason you need to remove the muffler in the future, it is a lot easier to unclamp it and tap it loose then it is cut it off. That way it can be reused.