Those clamps came with the Solo cat back I put on early Spring and so far so good.

 

The only problem you have is the muffler is made with 2.5” pipe and the stock is 2.25”
The Magnaflow 11385 is 2.25”. It’s a shorter than the 12468. It is the same size 4“x9” X14” that
Solo uses as a Mach shorty. It will likely louder than the stock mid muffler at WOT, but the X pipe will keep it close at part throttle.

 

Mmhmm. I guess when I looked at the direct link Google gave me to Magnaflow's product page, it was for the 11385 and I didn't notice, then I went to Summit and ordered 12468.

I see more than one reference and some pics of the 12468 welded to stock midpipes. So is this really a problem, or would I just need to get adapter clamps and not butt clamps?

 

Yes adapters or see if your exhaust shop can swedge the muffler pipes down to 2.25”. Almost as important to have the crushed pipe between mid muffler and the resonators replaced. It’s all welding and not DIY but it’s what you will want.

 

I was just under it to take a closer look. I found the heat shield had wallered out around the two screws that flank the muffler and it was hanging down on it. I re-secured it with large washers. We'll see how long that lasts. After that I had to start it up because I couldn't see any obvious leaks. The sputtering seems to becoming from the top of the body of the muffler.

Since you mention getting rid of the crushed pipes aft of the muffler, will there be clearance issues with the tunnel brace afterwards?

 

My midmuffler had the same leak on the top. I replaced it with the 12468 and removed the pipes and the resonators. The shop was supposed to cut out the small cats (2009.5 only) and mount the 12468 far enough forward that i can still use the tunnel brace. Welder decided that he had a better idea, kept the mini cats and 12468 is huge so I can't put a tunnel brace any more. also 12468 is so huge that it is easy to scrape. I wish I knew about 11385/6 earlier. Oh well, it's a temp solution till I decided what the exhaust end goal is going to be. Meanwhile, car is extremely quiet in the cabin. Stock like if not better. No drone with DOD on. Almost dangerously quiet because on part throttle you can get in to very illegal speeds very quickly and effortlessly. If you are planning to use the exhaust for awhile, get the 11385

 

Your leak is likely from the seam on top of the mid muffler. Had my first GT mid muffler replaced with an xpipe. Shop placed a 1/2” wood on top of the of the brace before welding. Weld it up, pulled the wood and no clearance issues and pipes are straight

 

11385 ordered. Thanks for the advice.

 

Ok, so I'm looking for sufficient pipe to run from the outlet of the 11385, far enough to get rid of the crushed pipe after the tunnel brace. That section is 2.25", correct?

Do I need a 2.5 to 2.25 adapter for the inlet of the 11385?

I also need to replace the rear flanges. Both the ends of the stock section and the flanges on the Solo axle backs are rusted and barely holding together. Very leaky sounding. Is all that also 2.25", or 2.5"? I'm figuring on cutting the ends off, including the flex section, and getting new stuff welded on.

I've done some googling and found various answers that some sections differ in size.

It's an early 09, so it matches the 08, FYI.

 

The advantage of the 11385 is that it is 2.25” id pipe. Be ready to spend some time grinding the inlet of the resonator to get the pipe out. This is how far a ground mine to get the pipe out.
Now for the flex and flange to the axle back muffler. I’ve found 2 choices. One is a heavier stainless flange and flex so the flange doesn’t rot out again. It is slightly longer than the stock flex, but the stock exhaust has enough straight pipe at the flex to handle it. Or you can make it look like a GXP exhaust and eliminate the flex. I found a 2.25” exhaust repair part for $30 on eBay

 

View attachment 182319

Do you have a link to this one? I've been looking and can't find it.

EDIT: NVM. I found one.

 

Thoughts on keeping or ditching the stock resonators?

 

I cut mine off and it doesn't drone with the xpipe muffler, though I have the bigger one. But yeah mine are gone and I'm happy with it.

 

If you are going to keep the stock mufflers in the back, you can loose them or keep them. They are straight through so no hp lost. If you have the AFM system and want to minimize drone, keep em

 

I have afm and Solo j-pipe axlebacks.

 

Keep them with the smaller 11385 muffler

 

Are Solo axlebacks 2.5"? Their website doesn't outright say. But they don't seem to make anything smaller.

 

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It's an old thread and alternatively can call or email them for more information.

 

I got under and measured.
Upstream of midmuffler: 2.25" od
Between midmuffler and resonators: 2" od
Between resonators and axlebacks: 2.25" od
Solo axlebacks: 2.5" od

 

Bought the separate flange and flex on eBay. Want to take out the restriction of the crushed sections after the mid muffler and the flexes at the back mufflers. Make the stock exhaust as good as possible.

 

Here's what I have on hand or ordered:

• Magnaflow 11385
• 20" of 409 2.25" tube to cut and replace the crushed tube aft of the muffler
• 2 resonators, Team Allied 3512RS, same body size as stock, with 2.25" inlet instead of stock 2"
• 2 full stainless flex/flange pipes, 2.25", happen to be made for 00-05 Taurus. 6" total length
• 2 pair stainless 2.5" flanges, 1/2" thick with gaskets.

From what I can tell, the 2.25" and 2.5" flanges will have compatible bolt patterns.

 

Your flex pipe is only 2.0” and is too long. I can almost guarantee it’s it’s not an interlink core either. The flange and pipe are mild steel. You want a 4” long 2.25” dia flex and a interlink interior thick stainless flange. Best flow. The stock resonator is 2 1/8” A little to be gained. I think you really have to look at your final goal.

 

The flex pipe specifically said 2.25". The 6" (actually 5.5", now that I read it again) includes about two inches of pipe that will slip over a 2.25" pipe. And it says stainless flange and flex portion. The flex is 2" long. Tbh, it reads very much like a good dimensional fit. I scrutinized my pics and measurements for a while before ordering.

I can't comment about the core. It doesn't say and I don't know what an interlink core looks like.

For 00-05 Taurus Sable 2.25" SS Exhaust Flange Cat Outlet Repair Flex/Pipe | eBay

2000-2005 Ford Taurus 3.0L 8th VIN# S. 2000-2007 Ford Taurus 3.0L 8th VIN# U. One side 2 bolt SS flange. 2000-2006 Ford Taurus 3.0L 8th VIN# 2. Welded with 2" Length SS Double Braided Flex Pipe. CNC Machine flange.

www.ebay.com

My goal is decent but not obnoxious sound, and to not be rusting off the car.

 

See photo above

 

If you are adding a cam or forced induction. Don’t waste one minute or cent modding your stock exhaust. I did the X-pipe for the mid mufflers and resonators. Replaced the rear flexes and modded the rear mufflers and made up Stainless Works mufflers with tips to bolt in. Ran that for years on my first G8. And it rad and sounded pretty good. Then Solo used my car to fit and create the 3” exhaust. I got a super deal for a 2.5” Mach Balanced System. Driving home from their shop I could instantly feel how much better the car was. And I had a mild set up. Intake , 1.85 rockers, shorty headers and Solo cats.
If I had known how much better the Solo exhaust was, I wouldn’t have cut up the stock one. If your car is stock and you want it to “sound” better. Either replace the mid muffler/crunch pipe for an X-pipe. Or a bit louder the Solo axle back. The stock 2.25 pipe barely supports the stock motor. You will be more satisfied with the mods you add if you have a proper performance exhaust. Solo, Magnaflow, Corsa Borla, Kooks or Stainless Works are some of the most popular. All will give better results than a chopped up stock one. I’m suggesting you pick what you do based on how far your mods will take you. Do it once with no regrets.

 

Got it welded up last week. Overall, not loud in the cabin at all. Actually quieter than it was before since there is no longer a hole in the mid-muffler.

Here's a cold start.

 

That does sound Good. That is why I want to add a pair of 8” to 12” perf core resonators to my Solo cat back.