Sport Muffler Caps

[Jeff Higgins]

I have shamelessly pirated one of songhoh's photos from his Florida RS / R drive to help me ask these questions: How do I make a pair of these caps, and what holds them on? My sport muffler is a bit on the loud side for daily driving. This looks like just the ticket, I just don't know how to make a set.

[BAPhotowerks]

The ones I have seen are simple metal cups, probably not too tough to fabricate once you found the right material and pipe with a tight ID. Mostly a mechanical seal, but with small bolts at 3 and 9 o'clock to keep them from blowing off.

Jeff, do you have the third outlet on your muffler or were you going to add it?

[Rico]

I think Autofarm in the UK did Songhoh's muffler / caps.
He would have to chime in on this, or you can PM him.

[Jeff Higgins]

I would have to add the third outlet on the left. It looks like a simple matter of hole-sawing a hole in the center of the welded over boss and welding on an outlet. I have an original single out I can use as a go-by for the length, diameter, and bend. That part should be pretty easy.

I was thinking of just attaching the caps in the same manner as chrome tips. A slight interference fit and a couple of sheet metal screws hiding down at 4:00 and 8:00. That seems o.k. for chrome tips that will stay on all of the time, but I'm affraid they would quickly develop some slop on caps that would be removed often. I was hoping there might be a more sophisticated way that the factory might have come up with back in the day, or that some one has come up with now. I would just hate to blow one off and hit that nice officer that has been following me around...