Retrofit New Thrush Muffler no Cat


Smarty450CDI

Remove old Muffler

Cut-off Old Pipes (2)  from muffler to reuse

weld pipes together and keep flanged end

Install pipe to muffler using flange and bolts

Install new thrush muffler using reducer fittings from 1 7/8 OD down to 1 1/2 OD

and weld or clamp together

Use existing support bracket and make 3/4 by 1/8 steel and bolt it to existing bracket

Require some mods to end of bracket for bolting strap

enjoy your new sound and better performance

Cost is around $ 150 plus your time

Muffler is Thrush Turbo Model 17704 at Canadian Tire or Online

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Sound clip, maybe...????     Hmmmmmmmmmmm.....I am already thinking about mine and I haven' even got it home yet! That folded seal leak is anoying me knowing it will sooner than later split....so why not solve it before it happens?
Thanks....oh mine's a diesel, if that makes any difference...?

 

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My 2002 Smart 450 Cdi still has original exhaust. As a precaution I TIG welded bottom fold full length using 316L stainless rods having read reports that is where they split. 

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This is a diesel CDI, The original muffler was plugged solid. This caused pressurization of the engine sump causing oil to blow out the seals.

New muffler remedied the oil leak and it runs and sounds great. MB wanted 700 for a new one of course.

This cost me 150 and it passed the emissions test.

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sticks out kind of low

 

 

and im curious whats hiding under the heat wrap

 

muffler is reversible is there any reason why you didnt go with a horizontal mounting using upper as an inlet and the middle as an outlet with an added down spout ?

 

 

Edited by LooseLugNuts
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What about a bike shorty?  Or a tube glasspack design with a step inside it.....too late for you now, but as a thought process?  Plus the oxygen sensor is it before all cats...? If so, has anyone thought about guting the cat? Yes I do realize this isn't correct legally speaking etc etc, it's just a question..lol.  Cats do get plugged also. I did see someone in the states doing this.....and i saw it was a two staged cat, so you could always take just half of it out, if that was you wishes..?  I also fully realize it's next to impossible unless you have a good exhaust pipe bended to get close ratio bends......unless you love to weld well...no offense...

The only reason I'm asking is sooner or later we all must walk down this road seeing as this is a known issue for the can's seam to split, so why not find a fix other than the stock costs...?

 

Augh.....the good old days of the Thrush Pecker.......love it!

 

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sticks out kind of low

 

 

and im curious whats hiding under the heat wrap

 

muffler is reversible is there any reason why you didnt go with a horizontal mounting using upper as an inlet and the middle as an outlet with an added down spout ?

 

The bottom outlet is just above the tubular frame bottom. So it should be okay for clearance.

The heat wrap was put on to cover the very rusty original and thin pipes from the old muffler.

I could have done a nicer job using new metal.

The muffler could not go the other way around due to clearance issues.

20180221_192610.jpg

Edited by Smarty450CDI

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I think purpose of heat wrap is to hide chicken welds.

 

As stated earlier The old pipes were pretty rusty and thin.

Anyway it works great and it cost little.

 

Edited by Smarty450CDI

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What about a bike shorty?  Or a tube glasspack design with a step inside it.....too late for you now, but as a thought process?  Plus the oxygen sensor is it before all cats...? If so, has anyone thought about guting the cat? Yes I do realize this isn't correct legally speaking etc etc, it's just a question..lol.  Cats do get plugged also. I did see someone in the states doing this.....and i saw it was a two staged cat, so you could always take just half of it out, if that was you wishes..?  I also fully realize it's next to impossible unless you have a good exhaust pipe bended to get close ratio bends......unless you love to weld well...no offense...

The only reason I'm asking is sooner or later we all must walk down this road seeing as this is a known issue for the can's seam to split, so why not find a fix other than the stock costs...?

 

Augh.....the good old days of the Thrush Pecker.......love it!

 

Yes there are probably better muffler options. I picked this up at Canadian Tire.

The Cat was in the old muffler so I don't have a Cat now. It still passed the emissions test.

I might revisit this fix at a later date. But for now it's doing the job.

Plus I like the sound.

Edited by Smarty450CDI

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1 hour ago, Willys said:

 Plus the oxygen sensor is it before all cats...? 

 

 

There isn’t one on the diesel.

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4 hours ago, Smarty450CDI said:

Here is the way it could be done with new pipe.

 

that looks closer to what i would have tried (id have a tighter bend and use the high inlet with a lower outlet)

 

but the muffer flow is backwards ..that one is not a reversible (note the A------>B arrow)

Edited by LooseLugNuts

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