Direct fit or universal mufflers
Most premium-quality performance mufflers and pipes today are made of
stainless steel (usually aircraft-quality T-304), but there are lesser
quality grades of stainless that sell for less. Aluminized steel is another
option, but it does not have the durability of stainless. Even so,
aluminized steel is much better than plain, uncoated or painted steel.
Most performance pipes are formed with mandrel bends which do not narrow the
diameter of the pipe where it curves. This reduces unwanted restrictions and
keeps the exhaust flowing freely. Most premium mufflers and systems are also
plasma or TIG welded to maintain the strength and corrosion resistance of
the stainless steel. Some manufacturers also use a process called bulge
forming or hydroforming to form steel sheets into molded shapes using
extremely high fluid pressure.
Performance mufflers are available in both direct-fit or universal
configurations. You will find the greatest selection in universal products,
which can be adapted and made to fit almost any vehicle. But the main
drawback of one-size-fits-all mufflers is that they sometimes require
cutting and welding pipes, and fabricating hangers and mounts.
When the stock muffler is removed, the existing pipe may have to be cut,
shortened or lengthened. If the pipes are getting weak, they may also have
to be replaced to complete the installation. New hangers are often necessary
to support the muffler, or existing hangers may have to be repositioned to
provide proper support and keep the system from flexing or rattling.
Clearance may be another issue, especially with large oversized muffler cans
that are not the same size, shape or length as the original muffler.
Making modifications to a stock exhaust system raises another issue. It may
complicate matters if you ever want to go back to a stock muffler. This may
not seem like much of an issue when your are installing the muffler or
exhaust system. But if and when you sell the vehicle, you may want to remove
the parts you installed and replace them with the original parts. So the
fewer modifications that have to be made to install a custom universal-fit
muffler, the better.
Direct-fit mufflers usually do not require modifications or changes because
they are designed to replace the stock muffler perfectly. Most are a simple
bolt-in installation that connect to existing pipes and have mounts that
line up with the stock hangers. The major drawback with direct-fit custom
mufflers is limited availability for less popular models.
Sound quality is something that is harder to control with universal-fit
mufflers than direct-fit mufflers, which have been engineered for a specific
vehicle application. Different engines sound differently and produce
different frequencies and harmonics in their exhaust systems. So don't
expect a universal muffler to sound exactly the same on different vehicles.
At the same time, some performance mufflers are tunable in that they have
removable baffles. You can change the sound by adjusting or removing the
baffles.