- Once the muffler is located, the vehicle will need to be raised using a jack at any of the solid points of the frame, axle or suspension and then secured with jack stands. Measure starting at the engine side of the front edge of the muffler, and then end about 6 inches back; find the center, and mark it with a scribe or grease pencil. Start drilling your first mark slowly with a small drill bit, about 1/8 inch, chucked tightly in your drill; use machine-type oil for ease of drilling. As the drill begins to cut, you may be able to go faster. Drill a couple more holes 1/2 inch on either side of your first one, staying on the 6-inch line. These new holes can be larger, about 1/4 inch. Never drill any holes larger than 3/8 inch.
- After the holes have been drilled, make sure the vehicle is secure and out of gear. Start the engine, and listen to it run. If it does not quite give the sound desired, repeat the process with more holes 1/2 inch outside the previous ones until the desired sound is achieved. Do not drill past the apex of the curve at the sides of the muffler. Always drill the bottom side of the muffler to keep water accumulation on the inside to a minimum. Test each time any new holes are drilled, and leave the vehicle running for only a short amount of time. Make sure the muffler has cooled before proceeding with more holes. If this still does not give the desired sound, you may measure forward from the rear of the muffler by an inch and repeat the whole process along that line.
- Carbon monoxide is now a concern with the new holes in your muffler, and installing a carbon monoxide card in an enclosed vehicle after this type of alteration would be a good idea. It is inexpensive, and you can pick one up at any automotive store. Your safety and security are important; know that the flow of emissions can change drastically because they are now able to flow out of the muffler before they reach the optimal location, which is the end of the tailpipe.
Drilling the Holes
Perfecting the Job
Finishing Up
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