DDK - Die Deutschen Klassiker

Hi,
I have just started to make a new silencer for the 912, not happy with the bulky, heavy standard unit, I have designed my own.

It will feature tuned length headers incorporated in the main box and will be made from 304 stainless steel, all sheet will be .7 mm and the pipe work will be 1 5/8, 18swg.
Twin pipes will exit under the rear valance

Not to sure how it will sound but there is only one way to find out !

Here are some pics. of progress so far :















Nick.

Beautiful welding !

Thanks Andy.

A little progress this week, i made the Jig using the original exhaust so the new one can be made on this.
I also got some of the internals made, the tubes are for alignment at this point.
And the end caps are now pressed out.

Nick.

Look forward to seeing the outcome of this

Nice work!

Got on quite well this week and the exhaust is starting to take shape now.
It's feeling quite light, I'll weigh the old one and see how much weight I am saving.

Some shots of the inside,









The whole assembly will be tacked together before being full welded, should be done next week.

Nick.

Lovely work: very impressive!

Just out of interest, what are you using for the pressing?

Cheers Barry,
I have used various tools for the pressings. For the end caps I used a miss-matched punch and die (small punch and large die) to make the swage, just pushed in to the desired depth being carefull not to break through !
For the small 'doughnuts' around the primary tubes I used a round taper punch (50 deg. taper) and a 60mm die with a radiused edge.

Done using a flypress, and a Pierce-all punch machine, but it could all be done on the flypress with the right tooling.

Cheers, Nick.

Well it's on and i've been up the road

Pics. soon.

Nick.

nickT wrote:Well it's on and i've been up the road

Pics. soon.

Nick.

and a video with sound please

Chris

Hi, some pics. of the finished exhaust and how it fits on the car.

I had originally thought that due to the light weight materials the note would be rather tinny and raspy but it turns out to be a deep, quite meaty burble, louder than the original but not too loud.
There is no packing in the 'bean can'.
I also weighed the old one, 11.1 kg or 24.4 lbs, my exhaust weighs in at 6.1 kg or 13.4 lbs !

Thats a 5 kg loss, great for a rear engine car.

It was trickey to weld up due to the thin gauge 321 stainless material and you can see some distorsion in the can.













Nick.

Superb !

A tremendous piece of fabrication! I've just come in from the garage after covering my embarrassing efforts on my brother in law's Stag in thick underseal

Thanks for the comments, it all worked out quite well really. I may do some more work to the tail pipes to quiten it down a bit, come and hear it at Heddingham !
Cheers, Nick.

Ok Nick i'll ask the question everyone one would like to know, how much would you charge to make one?? as ii'm on the lookout for one myself and this just fits the bill Regards Allan

Nick, good to meet you en-route Hedingham. Didn't put 2&2 together at the time ..... would have loved to have heard the exhaust