Can this muffler be modified to fit a Type I?

Hi All -
I have been doing searches on both this forum as well as the spyder forum on the dreaded carrera muffler topic. I just received one of the mufflers made by VS that has the single "cherry bomb" style muffler that is parallel to the rear bumper, with the two larger baffled beetle style tips. My plan was to cut the tips off, weld the thing closed and then cut in a single center pipe (a slightly "squashed" 4in pipe) to better mimic the carrera.

Then I found this:
http://www.vw-online.co.uk/acatalog/Karmann_Konnection_Carrera_and_Racing_Parts_7.html

I know very little about 356 stuff - especially the dimensional differences between a 356/912 motor and a type I. Does anyone know if I could simply change the flanges on this muffler and get it to line up? Has anyone built anything custom to recreate this?

I know it is a tad pricey, but I enjoy the original look (I have to address the location of the ebrake next....)

Thanks!!
Scott S

Too much work to adapt the pictured muffler. It would be a whole lot less expensive if you found a custom exhaust fabricator close to where you live and have him make you a similar looking system that exactly fits your car.

Forgot to mention.
At today's rate that muffler assembly costs $1,156.90 US dollars. I bet someone could make that or a similar system for around $600 to 700 dollars or a little more than half of the indicated cost of that system.

Look around your neighorhood for a muffler shop that caters to hot rodders. The guy I used appreciates the problems of custom and unusual cars. I think he rather enjoys the challenge. In my case I drove in with my aftermarket header all ready installed (and a junk muffler held on be some coat hangers) and he supplied my new muffler, resonator, exhaust tip and all connecting tubing.

Hi David -
I was informed we have a new local Beck builer here in town. I dropped him an email with a pic of the muffler and he is going to see if he can build it for a reasonable cost. Even at 500.00, that is still 30% of the other system. Told him there may even be a market for them if they perform.

Interestingly, the manufacturer of the system I posted above said I could easily just change the flanges. However, after some more research, it appears that the 356/912 only share port demensions with the early 36 horse motors. The 1500 and on up Type 1 is 2.5" wider. That would be a pile more work over and beyond just burning on some new flanges.

Scott, as I mentioned in my post above, why not eliminate the middle man and go directly to a fabricator??? More than likely, the Beck builder will mark up the final product and you'll pay more money

Hi Larry -
The beck guy is a fabricator. I spoke to them again through email and they think they can build it - just a matter of time and cost. I think it could be a neat winter project. I am heading over to their place during lunch at some point next week and will report back if anyone is interested.

Just to be up front, I am not trying to fool anyone that the car is real/etc. I just think if doable, having some of this detail stuff done would be pretty neat. Although, per my post above, after some research, moving the ebrake to an umbrella handle style up under the dash looks like it will be quite the chore....

Try to make this up from a few pieces of aftermarket exhaust systems this will save you a bundle.

Scott I'm working on a header as we speak using a magnaflow muffler
it should fit most of the speedsters it's using a header and it will have dual or single pipe about a week I'm going to be fitting one on kirks car's after that I'm going to dyno one of my motor's to see if flow's good I'll have pic's soon . Roland

Roland - are you up for a before and after comparison of your new exhaust? If so, please share how the engine is dressed on the dyno (air cleaner, fan, exhaust and mufflers). Inquiring minds want to know! Thank you.

No problem

I put the "stop gap" muffler on last night. It is the dual outlet made by vintage speedsters (looks like the Tri-Mill but the tips are lower to clear the body). The thing bolted up great, car sounds wonderful and idles great - but lets out a single back fire on decel after reving the motor above 4k that includes a very pretty 6" flame out of each tail pipe. Timing looks to be right on (but even adjusting it one way or the other does not eliminate the back fire). Carbs respond quickly to mixture changes and the unisyn shows an equal draw. I think I have a jetting issue (car came from sea level and is now at 6000 feet) or it needs a valve adjust. Sick of futzing with it and dont have the time to chase jets, so off to a local VW shop it goes. Probably a good thing as it only has 750 or so miles on it and has most likely never been gone throgh since the original build. I am bummed. Oh well...

The muffler is probably trapping of raw unburned fuel in the exhaust, lean out the mixture a bit and try that.

I don't have any exhaust comments, but did anyone scroll down (Karmann Konnection's site) and look at their steel/alloy wheels? They look nice.

I concur with Alan. 6,000 ft is way up there in that region known as "rarified air" (That's what the executives on my department thought they were breathing as they occupied space in the ivory tower)

With out a doubt, you're running rich.

Hi All -
Just had a great result modifying the VS version of the Tri-Mill.

I ordered the VS tri-mill in raw steel (no powder coating/chrome tips/etc). Having this finish as an option, coupled with the fairly inexpensive price tag, made this the perfect choice to try some modifications in my eyes. Last night I cut off the tips, welded them shut, then cut a hole in the center and added a single 3" tip that I shaped with the vice to achieve the correct look of the carrera flat/squared oval.

The car sounded pretty darn good with the stock VS unit (boy is that sucker built well - it was work cutting and grinding those tips). The car now sounds absolutely fantastic! I cant tell you how pleased I am. The tone frequency is a very low at idle, and there is no "ratty-ness" as the revs build. It is probably 15-20% louder than the stock VS muffler. Being that the car is a carrera look, the sound fits the car perfectly.

Man.. I am just so so so pleased!!

No camera last night - I will snap some pics next week.

Oh, and while I am confident the car is running rich, the new muffler eliminated the back fire completley. Found a few black streaks on the old muffler flanges/head surface and some spatter on the the heater boxes - the car had exhaust leaks everywhere.

Excellent! I love it when a plan comes together. Your custom fabrication should make your driving experience that much more enjoyable.

Remember, anytime you switch from a "standard" exhaust to an engineered header/collector system with a low back pressure muffler and exhaust, you should seriously consider re-tuning your carbs. Preferably, using a dyno, or at least an oxygen probe up the tail pipe. You might be giving away both gas mileage AND horsepower, not to mention valve life. Just a thought.