the install of my TiiCo conversion, I noticed that the exhaust
fitting was going to be a little more challenging than that of
the stock setup. I tried for maybe 1/2 an hour to get the muffler/cat
to line up and bolt to the new exhaust header. After I failed
miserably I asked for help for the Vanagon List. One response
I got was from Kyle Wade. Here is the info that he gave me regarding
the fitment of the muffler/cat.
you remove the tailpipe (mine just unbolted, but I guess some
have to be cut off). With my kit, on the mounting bracket on the
passenger side of the van there were 2 bolts pointing toward the
driver's side that held the rubber piece the exhaust bolts to.
These bolts looked like they'd get in the way of the bracket,
so I flipped them. Now the bolts are pointing toward the passenger
Kyle told me that some late model V'gons had a heat shield attached
to the muffler. This needs to be removed (luckily my van didn't
have this). Then drill the holes in the exhaust brackets as per
the directions, but don't install them on the van yet. Next (it's
much easier with a helper) you attach the cat/muffler to the TiiCo
exhaust pipe with the OXS pointed up toward the air filter. After
you have the cat/muffler bolted to the exhaust pipe, check the
clearance between the muffler and the belts/bodywork. I had to
bend a portion of the bodywork near the passenger side tow loop
away from the muffler so it would clear (actually, even after
I got it to fit, there was so little clearance that when I started
the motor the end of the muffler body still hit the rear valence).
Then you attach the passenger side exhaust bracket to the muffler
and get it to slip over the ends of the bolts on the rubber mount.
funny thing is that hole you drill in the driver's side bracket.
The directions never say what it is for. It's for the strap that
goes over the cat. Instead of hooking the strap in the original
hooks, the post goes in that hole. You have to grind away a 1"
or 2" section of the wider part of the strap so that it matches
the width of the narrow part at the end that goes between the
stock hooks. Once the passenger side is up and not interfering
with the bodywork or the belts, then you install the driver's
side bracket. I had to push the cat up about 1/2 an inch to get
the mounting holes to line up. I installed the strap on the driver's
side bracket before I installed it. I found that it would be darn
near impossible to get the strap on after the bracket was installed.
my case, there was no way to install the muffler without having
it rattle against the bodywork. Needless to say, I got tired of
that rattle after about 200 miles of driving the conversion (luckily
it only rattled when going into reverse and when idling). I then
searched the internet for viable solutions to my muffler problem.
The solution that I found was a Magnaflow
muffler. The part number is 10434. It has a 2" inlet/outlet
and a 4" diameter body (as opposed to the stock muffler's
6" body). The tone of this muffler is much more noticeable
than that of the stock muffler and it isn't as quiet. It should,
however, give a little better performance. The gentleman who installed
the new muffler was very forgiving about me hovering over his
shoulder during the installation, and he did an excellent job
fabricating a mount that bolted right to the TiiCo muffler bracket
(as soon as I get some good daylight, I'll crawl underneath and
take a picture of that as well).
are a couple pictures of the clearance between the new muffler
and the bodywork.
many thanks to Kyle Wade for his help!