Tom F&L GoR
Enthusiast
When I bought my '94 it came with a 3" Hennessey sidepipe system. Extremely buzzy in the car. I replaced the straight through muffler with a SuperTrapp muffler (the kind with the plates on the end to adjust the noise/backpressure.) It cured 80% of the buzz, but due to rules changes at Lime Rock Park, was too loud. I then replaced the SuperTrapps with 3" Spiral Flow mufflers and the noise level went up and the annoying buzz in the cockpit was worse than ever.
Then I saw a Gen 2 complete exhaust system in the Classifieds. (<--- mention for VCA Classifieds!!) I bought it.
Euro Gen 1 cars had some type of rear exhaust (shown in the parts manual, not the service manual) and I compared the underneath of Gen 1 and Gen 2 cars at Tator's Dodge - it seemed like everything should fit. And, I had already replaced the Gen 1 cast manifolds with the Gen 2 stainless manifolds, so the hard part was done.
Key notes:
There is a left and right side for the flex pipe and catalyst. The passenger side pipe connecting the manfold to the flex pipe is shorter because the engine sits over to the right side.
The side pipe covers fit over the Gen 2 exhaust just fine.
The front isolator hanger is the same. The rear hanger on the Gen 1 is in the wrong place. Also, the Gen 2 hanger bars welded to the pipe are just after the bend exiting the muffler and I removed them. It seemed to hang the pipe lower than the floor of the car and I didn't want it to be the lowest part of the car. While I made a new hanger by drilling and tapping holes in the floor, better welders than me should attach the metal rods as used on the end of the Gen 1 system on the Gen 2 pipe. It would be simple, clean, and work perfectly.
The pipes out of the muffler reach into the frame around the differential without hitting anything. You will need to plug the downstream O2 sensor holes - I used old spark plugs with the same M18x1.5 thread.
The big difference is the Gen 2 muffler. The Gen 2 muffler has two inlet pipes and two outlet pipes with chrome tips. There is a large cutout in the rear fascia to accomodate the muffler, which the Gen 1 does not have. I cut the pipes and tips off the muffler body and attached the tips to the end of the pipes. Luckily the pipe diameter of the tips is larger than that of the pipes, so they slip over. This positions the tips to turn down and rearward just at the leading edge of the rear fascia, so I did not have to do anything to the fascia. I'm sure it will get exhaust stains on it, but it's far underneath, can't see it, and I'll save that for another project. Meanwhile, the tips face rearward and are not below the level of the frame rails.
Lastly, on the x-brace behind the differential is a bracket with two threaded holes. It seems like this should have lined up with tabs that were welded onto the pipes leading into the muffler, but I just couldn't get it close enough to use them. (There is a rear exhaust isolator hanger that I didn't have, so maybe that was the secret.) Anyway, I cut the tabs off (which also let me slip the chrome tips onto the pipes as mentioned above) and used traditional muffler hangers.
It's all done and terrific. As I mentioned, the preceeding muffler changes only made things worse, so this is a huge, huge improvement. I can talk to passengers, hear the phone ring (I don't answer, that's illegal in NY) and don't have to have the V1 turned up so loud. For all you Gen 2 guys, you obviously know what it sounds like. Stories say that the Gen 2 system accounted for 15hp over the restrictive Gen 1 sidepipes, so you aren't losing anything. For you Gen 1 guys, it's a viable option.
And yes, I made some false exhaust tips for the sidepipe covers. I guess I now have fourple exhaust.
Then I saw a Gen 2 complete exhaust system in the Classifieds. (<--- mention for VCA Classifieds!!) I bought it.
Euro Gen 1 cars had some type of rear exhaust (shown in the parts manual, not the service manual) and I compared the underneath of Gen 1 and Gen 2 cars at Tator's Dodge - it seemed like everything should fit. And, I had already replaced the Gen 1 cast manifolds with the Gen 2 stainless manifolds, so the hard part was done.
Key notes:
There is a left and right side for the flex pipe and catalyst. The passenger side pipe connecting the manfold to the flex pipe is shorter because the engine sits over to the right side.
The side pipe covers fit over the Gen 2 exhaust just fine.
The front isolator hanger is the same. The rear hanger on the Gen 1 is in the wrong place. Also, the Gen 2 hanger bars welded to the pipe are just after the bend exiting the muffler and I removed them. It seemed to hang the pipe lower than the floor of the car and I didn't want it to be the lowest part of the car. While I made a new hanger by drilling and tapping holes in the floor, better welders than me should attach the metal rods as used on the end of the Gen 1 system on the Gen 2 pipe. It would be simple, clean, and work perfectly.
The pipes out of the muffler reach into the frame around the differential without hitting anything. You will need to plug the downstream O2 sensor holes - I used old spark plugs with the same M18x1.5 thread.
The big difference is the Gen 2 muffler. The Gen 2 muffler has two inlet pipes and two outlet pipes with chrome tips. There is a large cutout in the rear fascia to accomodate the muffler, which the Gen 1 does not have. I cut the pipes and tips off the muffler body and attached the tips to the end of the pipes. Luckily the pipe diameter of the tips is larger than that of the pipes, so they slip over. This positions the tips to turn down and rearward just at the leading edge of the rear fascia, so I did not have to do anything to the fascia. I'm sure it will get exhaust stains on it, but it's far underneath, can't see it, and I'll save that for another project. Meanwhile, the tips face rearward and are not below the level of the frame rails.
Lastly, on the x-brace behind the differential is a bracket with two threaded holes. It seems like this should have lined up with tabs that were welded onto the pipes leading into the muffler, but I just couldn't get it close enough to use them. (There is a rear exhaust isolator hanger that I didn't have, so maybe that was the secret.) Anyway, I cut the tabs off (which also let me slip the chrome tips onto the pipes as mentioned above) and used traditional muffler hangers.
It's all done and terrific. As I mentioned, the preceeding muffler changes only made things worse, so this is a huge, huge improvement. I can talk to passengers, hear the phone ring (I don't answer, that's illegal in NY) and don't have to have the V1 turned up so loud. For all you Gen 2 guys, you obviously know what it sounds like. Stories say that the Gen 2 system accounted for 15hp over the restrictive Gen 1 sidepipes, so you aren't losing anything. For you Gen 1 guys, it's a viable option.
And yes, I made some false exhaust tips for the sidepipe covers. I guess I now have fourple exhaust.
I'm a poser though. Washed the car this morning 
