'85 Muffler Replacement - What a PITA

[Strife]

So, I was successful with replacing the muffler on my '86 560SL, so I thought that I'd replace the 380's, which was in much worse condition - basically, it was held on by approximately 1/2 of one of the rear tailpipes. I have no doubt that it was the original muffler (it had the star on it). The 380SL muffler is welded on, whereas the 560's is done with flanges and metal gaskets. The idea is that you measure, cut the pipe, and slip the new muffler on. I bought an Ansa (alright, the cheapest, hey, it's a driver) muffler for this. I did paint it with a POR-15 clone, though, because I think it looks better black (the ANSA is just zinc plated/coated).

Well, not to my surprise, I had to cut behind the weld (the weld was pretty messy and there was no way another pipe was slipping over it). Using a chain type cutter was VERY difficult because there isn't nuch room between the pipes. Well, unfortunately, even after cutting as close to the weld as possible, this left the system about 1/2" too short. So, I put two adapters on it. This, of course, left it a little long. You are supposed to allow it to be 10mm short to allow for metal expansion. At this point, I just hung it up on my newly purchased metal-reinforced hangers, made it reasonably even, and tightened the clamps.

It turned out OK, but my system is still a bit loud - I suspect that my center muffler, which is supposed to do most of the muffling anyway, is a can of iron oxide. This is even MORE expensive than the rear muffler. Oh, well...maybe next year...anyway, it probably won't fall off now, and it SOUNDS powerful...