Exhaust

[rollingpinz]

One of my summer projects will be the exhaust. The muffle is a bit rusty and I don’t like the tail pipe routing. So I have a couple of questions.

Where can I get that 2 hole flange? I found one by mazdatrix and they’re local, but the middle most holes are not centered. There are places that do water jet cutting, but it seems crazy to spend that kind of money on something like that.

Is 1 1/2” too small? I read 1” for every 100 hp. So, 1 1/2” seems perfect.

[Stumbler]

Exhaust is pretty much straight forward. Are you talking about the flex joint? The motion of the Pinzgauer and thus the muffler and the relative stiffness of the headers bolted to the head requires that flex piping just before the muffler. You can buy one at https://swissarmyvehicles.com . They would usually have it in stock. The mufflers, headers, and especially the heat exchanger are difficult to find or if you find them, they are expensive. I would suggest that you inspect the muffler for cracks, especially around the intake, and then weld up any holes (assuming you have the stainless version) and then get them all ceramic coated before reinstalling. Ceramic coating goes on just like powder coating and it helps a little with heat retention in the heat exchanger. Note: the inside of the heat exchanger is an aluminum baffle, so you don't have to worry about rust except on the outer shell. I did all this almost 10 years ago and my exhaust, from the headers to the tail, look like new and perform like new.

Hope this helps.

[rollingpinz]

I was referring to the 2-hole flange on the back of the heat exchanger. Since the original 2-hole inlet muffler is no longer available, a Y has to be created for a single inlet muffler and it needs a 2-hole flange to bolt up to the heat exchanger.

Also, I’ve seen round mufflers that would be an easy fit, but the tubing size is 1 1/2”. Is that too small? Does it need to be 2”?

[pcolette]

The reproduction of the original muffler is available from SAV.

https://swissarmyvehicles.com/pinzgauer ... with-bolts

[rollingpinz]

Perfect. Thank you. Not sure how I missed that. I kept finding the discontinued one.

[rollingpinz]

The muffler arrived and is installed. It was a challenging install. I installed the “renovated” heat shield using the front bolts, then I put in the hanging straps. I attached the muffler to those first. Then I wrestled with the front end of the muffler and the back end of the heat exchanger. It was a struggle to get the holes lined up. I actually broke 2 of the bolts. Then I noticed that the gap was bigger at the bottom. This meant that the rear of the heat exchanger was sagging. I raised it with the jack. The bolts lined up and it was just a matter of dealing with 2 wrenches it tight spacing. Just in case any one is considering the SAV muffler.
I’ll fire it up tomorrow. I’ve been wrenching for over 8 hours.