I've been wanting to replace the factory exhaust on my TT2 for some time. I've seen the aftermarket offerings and thought it would be fun (and cheaper) to build one myself so I bought a muffler/resonator, flange with gasket, elbow/tip and 2 clamps (I don't have a welder) from Amazon. I'll provide links below. I knew the dimension from exhaust manifold to centerline of the tailpipe is 20" (Gen 5 is 19") so all the pieces had to fit in that space. The dimensions provided from the sellers led me to believe they would be a slip fit . Well, then the parts showed up along with reality and I had to Dremel the flange and elbow IDs a small amount to fit. https://www.amazon.com/dp/B0CQ87CVX7?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1 https://www.amazon.com/dp/B0B8ZCJL4Q?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1 https://www.amazon.com/dp/B0DS2LW2K3?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1 https://www.amazon.com/dp/B08P54MKMX?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1 Here's the loose fit assembly ready for install: Removing about 30 pounds of factory stuff. Install the new, close the cover. So I fire it up and it is so LOUD I can't stand it . I ordered 3 different inserts , called DB Killers, and will install them when they arrive. Hopefully that will quiet it down. Stay tuned.......
Looks good. You may find extending the outlet pipe beyond the edge of the truck will keep the back cleaner. Also, a turn out behind the rear tire might help with noise. Is it boom boom loud or raspy, tinny loud? If raspy or tinny they SS is too thin.
It's straight thru with inner perf stainless tube with f'glass wrap. The seller calls it a Universal Muffler and also a Resonator . I got the first insert and shoved it in the inlet end. It sticks into the muffler about 5". Much better but still too loud. Boom, boom loud with lots of resonance. The second insert (style E from below link) will go into the opposite end of the muffler and the third (style C), if necessary will go into the tip. https://www.amazon.com/dp/B0CQSD9BZN?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1 Style A
I had the style E type in my GPR muffler on my Moto Guzzi Norge. It made it a little quieter. I removed it when it started to rattle.
The one I have didn't quite fit into the muffler so I slit the stainless ring with my Dremel. Eight slits kinda equally spaced around the circumference and gently tapped it in. Very snug fit so no rattles for now. We'll see what the heat and cool cycles do with that!
Received the 2 baffles from Amazon and installed one in the end of the muffler. Had to rework it to fit, similar to the first one described above. I slit it 8 places around the circumference and had to grind a little off the OD. Tapped it in with a socket so it should stay in place and not rattle. Did a cold start and it sounds pretty dang good ! No rattles and no exhaust leaks so far. Haven't had a chance to take it for a drive so I'll hold my enthusiasm for now. Will do that later today. I have one more baffle in case the test drive goes awry. It will install in the tip and fits fine, no rework needed. So far I'm in $166.71 plus my time. The muffler from Oh Kei Garage is $399+shipping if you can find one in stock. I got a quote from Oiwa Garage for their Growler muffler for $457 shipped. Thoughts and comments welcome!
Just got back and the sound is great! No resonance at speed in the cab and a pleasant tone out the back. Almost too quiet, might remove the second baffle and install the tail pipe one. I'll live with it for awhile before making any changes. Pretty happy with the outcome! Let's see if this soundbite works, camera on the ground about 5-6 ft away and 30 degrees left of the tailpipe. https://photos.app.goo.gl/J5qAN5mFRY3aWmfN7
Thanks JJ! Yeah, I like it too! When I heard it for the first time with no baffles I thought I bought the wrong muffler . I went back to Amazon and put the Evil Energy muffler in my cart thinking to try that next. I forgot about it but a couple days ago my wife ordered some stuff and the muffler got ordered along with it. I guess I’ll swap it out when it gets here and see what it sounds like. I have a friend with a Sambar dump who is interested so maybe I’ll order the rest of the parts to build him one. This is kinda fun! I’ll see if I can do a cold start soundbite tomorrow morning.
I click the link and it made me make a request for access. I picked viewer. Supposedly I'll get a link in email if approved.
Looking back at the cost, I didn’t use one of the baffles and there were 2 flanges included so I have one left over for the next build. Bottom line is $130.88 all in. Also, I found some DB Killers on eBay for a killer (sorry) deal, about half of what I paid. https://www.ebay.com/itm/389671951664 The most difficult part was removing the factory exhaust, maybe 45 minutes to an hour. I was fortunate that all the bolts came out without stripping or breaking. Soaking with penetrating fluids is highly recommend. I will re-install the heat shield that covers the exhaust manifold.
Sounds very good, and nice writeup and photos to document the parts & install! The weight savings are a nice bonus too, and thanks for catching that. Just curious: Your tailgate says it's a SC motor but I didn't spot an O2 sensor, is that right?
Thanks! The oxygen sensor is in the exhaust manifold. You can see it best in the pic of the factory muffler. It’s between cylinder 4 port and the muffler flange on the back side.
Ah gotcha! I see it there now. For some reason I thought the O2 was located just after the exhaust flange, around where the flex coupling is.
