pictures of the STi exhaust on 92 SS, HOW TO, flange, hanger

[Bheinen74]

So, today I took off the original rusty muffler, and measured, modified the STi exhaust. Here is a breakdown and some pictures on the link. This did not require any new muffler hangers or rubber holders.

pictures link:

http://pg.photos.yahoo.com/ph/bheinen/d ... pg&.src=ph

Basically, keep the current oem midpipe on the car. Remove old muffler. Cut off 3.5" section of the very front of the old muffler pipe keeping the flange attached to this pipe. This pipe will be the 3 1/4" extension. You need to buy another solid flange (i got my special order at napa) for the end and this flange needs to be welded to the old 3.5" section that already has flange on one end. the flange i got was able to go over the pipe, and welded, then ground flush, see measurement -----------> note here.....:

***For the 3 1/4" extension flange, that measurement is flange to flange, outer measure.

On the STi muffler, cut off the back outer driver side muffler hanger so it can be shortenend and then butt welded back Cut the hanger where it is the straight part.. See my picture for the butt weld details.. It needs to run parallel the hanger on the right passenger side. The passenger hanger is PERFECT as is, no need to change or even to bend.

The old OEM center hanger needs be torched off the old pipe and keep the hanger in one piece. On the new STi muffler, hacksaw off the hanger and throw that hanger away. Have an exhaust shop weld on the old hanger to the new STi muffler. Have them weld it to what remains of the old weld bracket. Weld to the old hanger piece only, no holes into the pipe that way. The dimension for the hanger placement is 8 3/4" from right above the inlet pipe, back of can to center of the exhaust hanger. It needs to be slightly higher than the 2 back hangers. (when installing, have to push up to reach hanger on body, and there should be around 2" between pipe and axle stub.

good luck, mine fit perfect the first time. I took all the stuff in to the welder, and when i returned it to my car, it all went on perfedt, good measurements are key.

please post comments in this thread.

The flange was like 5 or 6 bucks at napa, the 2 new flange gaskets 2 bucks each. The welder charged me 25 bucks for the torching/welding. I did the hacksawing and measuring myself, with Dad's help installing.

[Legacy777]

Nice write-up!

Looks good!

[Imprezive]

hmm, I'm planning on making an adapter flange for an sti muffler, but it will be a 3" to 2.5" instead of the stock legacy dameter.

I think I might make my muffle sit a little farther in so the exhaust tip doesnt stick out so much, but I dont know, thats a lot of welding and it may not look so hot. I love the look of the STI muffler, theres that little bit of bling but still sleeperish at the same time. Its quiet enough to not draw too much attention but it gives a good burble to.

[Bheinen74]

3 1/4" length extension.

The inner diameter is 2.5 for Turbo and for STi.

the STi exhaust sound is quiet. sounds good, no rice.

[gt2.5turbo]

holy camera flash i have a headache now from teh brightness....


looks cool though

[Adam West]

Awesome. What was the total cost on this mod. Depending on the cost of the STI takeoff it had to be cheap...

[greg donovan]

bump because i should have found this a long time ago.

good write up.

should be inthe exhaust section.

[206er]

i liked doggy haircut better, but good writeup nonetheless.

[NuclearBacon]

can you relink the pictures? i see a bunch of pics...but not sure which go to this thread....

awesome write up and bumpity bump for an old post!