Muffler ? again - 986 Forum - The Community for Porsche Boxster & Cayman Owners

Allen K. Littlefield · 05-31-2011, 07:03 AM

For those of you who installed a "performance" muffler I have a few questions. If you removed your rear bumper for easier access, what did you use to re-install the plastic rivets you drove out of the spoiler? Porsche parts or a substitute?

For those who installed muffler without removing the bumper was it that much of a bear or just a PITA? I will have access to a lift so I won't be crawling around underneath a car on jack stands so the job should be a bit more civil. Any extra installation tips appreciated. New muffler only weighs 18lbs so any increase in performance I suspect will come through lb loss plus quicker heat dissipation.

AKL

insite · 05-31-2011, 09:22 AM

i have done it both ways. if you're removing the STOCK muffler, i recommend you pull the bumper. lots of aftermarket light weight stuff is no problem, but the OEM is pretty heavy & you'll appreciate the extra room. only takes a few minutes to get the bumper off anyway.....

as for the plastic rivets? they are CHEAP from the dealer. if you want to re-use your old ones, i have seen little snippets of coat hanger used to replace the center pin in the old rivets. i.e. you insert the rivet into the hole & then insert a segment of coat hanger into the rivet itself.

MN 986 · 05-31-2011, 10:01 AM

I replaced my OEM muffler with a FVD 'sound' version muffler that has about the same external dimensions without removing the rear bumper. I read opinions on both sides and I figured I'd take the bumper off if needed, but it went pretty smoothly leaving it on.
Good luck with the project!

Allen K. Littlefield · 05-31-2011, 11:15 AM

...both suggestions very helpful. Will let you know my 'outcome'.

AKL

tommy986 · 05-31-2011, 11:29 AM

I have a 2000 S, and ended up having to remove the bumper in order to get the muffler re-installed. Came off easily with the bumper on, but couldn't get the upper bolts to line up for re-installation.
I re-used the plastic rivet pieces. You just have to make sure you are careful to retrieve them after you tap them out.

ddb · 05-31-2011, 01:32 PM

I too removed my bumper cover (and under-assembly) to remove my OE muffler when I installed my first aftermarket muffler.

When I removed the first aftermarket muffler to replace it with my current muffler, I easily did it with the bumper cover installed.

I also re-used the original fasteners.

Jake D · 05-31-2011, 02:37 PM

Im not real sure what my fasteners were then cause they were metal and a PITA to get out. I installed mine with the bumper on. I struggled some for sure but got it done. I have some leaks around the muffler though because the bend in the "C" pipes is just slightly off. Any suggestions on the "C" pipes or should I just cut and weld them to fit. I asked a few exhaust shops in the area but they said they can't bend something that tight