KR Muffler Polishing and Installation

[6-Speed]

I just received my KR mufflers (Ford Racing PN M-5230-S) today. They are pretty ratty looking right out of the box with lots of residue on both ends - probably a byproduct of welding.



A TS member previously wrote about cleaning the ends with an Aluminum polish so I decided to give it a try. I used Mothers Mag and Aluminum polish and cleaned off the ends. Real easy process and it makes the mufflers look way better.





Now I just need to get around to installing them.

[TOMMY GUN]

What are you waiting for?




.

[gr8snkbite]

very nice. i hope it was only residue...

[GRABBER]

Man, you sure made those look nice.

Nice work.

[6-Speed]

Originally Posted by TOMMY GUN

What are you waiting for?


.

That's tomorrow's project.

[6-Speed]

Originally Posted by gr8snkbite

very nice. i hope it was only residue...

Many folks, myself included thought that discoloration on the muffler ends was rust when pictures of the KR first surfaced. I don't know for sure what it is but it's not rust.

[VaporDude]

Don't forget the step by step photo installation thread. We all need pictures of the install. Also we need a before and after video of the sound.

[cheftjpeck]

great job......looks awesome

[Joe G]

Nice polish job.











Ummm... that didn't sound right.














I mean, way to rub it out.




Ummm... nope, that's not right either.














Clean pipes.





Yeah - that'll work.






-

[Birdman]

That's more like it ......installation....?

[6-Speed]

As requested here are step-by-step instructions that I followed to install the KR mufflers on my car.

The muffler I installed on the driver's side is the one on the top as shown in this photo - note the rear hanger pin is installed higher up on the pipe (closer to the inlet end). Everything fit and aligned properly so I assume this is correct.



Here are the tools & supplies I used to install the mufflers:
1. 13mm combination wrench with a ratcheting box end (this will be your friend while removing stock mufflers - a very useful tool)
2. 16mm combination wrench
3. 3/8" ratchet wrench handle with 13mm (deep & std), 15mm & 16mm deep sockets and an extension.
4. 3/8" Torque wrench.
5. Anti-sieze (optional)

I backed up my car onto ramps to raise the rear end up allowing more room to work under the car. Apply the parking brake and block the front tires.

I started by removing/replacing the stock muffler on the passenger's side.

1. Loosen the muffler clamp with a 16mm deep socket or wrench.



2. Loosen and remove the two bolts on the front hanger/isolator. I used a 13mm ratcheting combination wrench which helps tremendously. The side bolt is not visible so you'll have to loosen it by feel.



3. Loosen the two bolts on the rear hanger/isolator and remove the side bolt leaving the bottom bolt attached (but loose) to support the muffler.



4. Make sure the muffler clamp is loose enough, then support the muffler body and remove the remaining rear hanger bolt and carefully wrestle the muffler out.

5. Transfer the two hanger/isolators to the new muffler - this is the passenger's side muffler.



6. This step is optional - I applied a small amount of anti-sieze to the threads of the four hanger/isolator bolts. I heard of one person breaking off a bolt while attempting to loosen it; this is to prevent that from happening.

7. Insert the intermediate pipe into the new muffler inlet and install the side bolt into the rear hanger; the side bolt is more difficult to align and is easier to do without the bottom bolt installed. Once the side bolt is started and finger tight, install the bottom bolt finger tight. This will hold the muffler in place. The KR muffler body is much smaller than the stock ones so there is more room to work when re-installing the hangers.



8. Install the side bolt into the front hanger. Once the side bolt is started and finger tight, install the bottom bolt finger tight. Tighten down all the bolts enough to secure the two hangers - I torqued these later.

9. The muffler inlet pipe must be mated to the intermediate pipe end such that the button bottoms out in the notch on the muffler end (see picture below). Then tighten the clamp with a 15mm socket. I torqued the clamp bolt to 40 lb-ft in a two-step increment - first to 35 lb-ft and then to 40 lb-ft.

You can see in the pictures below that there's much more room to work under there and access the hanger bolts with the smaller mufflers.



10. Finally I torqued the four hanger/isolator bolts to 18 lb-ft.

11. Repeat steps with driver's side muffler (photos below). I have heard that on some cars, one of the two driver's side muffler hanger/isolators is mounted with three bolts instead of two.





Make sure the tips do not come into contact with the plastic diffuser. The tips on my car centered up well so no tip alignment was neccessary on my part.

You'll notice the difference as soon as you fire up the engine. I am very happy with these mufflers!

[68fastback]

...looking good so far!!

[JTB]

Originally Posted by 6-Speed

I just received my KR mufflers (Ford Racing PN M-5230-S) today. They are pretty ratty looking right out of the box with lots of residue on both ends - probably a byproduct of welding.



A TS member previously wrote about cleaning the ends with an Aluminum polish so I decided to give it a try. I used Mothers Mag and Aluminum polish and cleaned off the ends. Real easy process and it makes the mufflers look way better.





Now I just need to get around to installing them.

You made the mufflers look fantastic, but a $700+ product shipped in that condition is a complete joke! IMO
And it is surprising as anything I have received for FRPP has been packed well and in good condition.

[6-Speed]

Originally Posted by JTB Consulting

You made the mufflers look fantastic, but a $700+ product shipped in that condition is a complete joke! IMO
And it is surprising as anything I have received for FRPP was been packed well and in good condition.

They're not quite $700; suggested retail is $599 and you can get them for much less. I agree, the manufacturer should have cleaned them off prior to shipping. However, it is an easy fix.

[Birdman]

Thanks for the install pics and instructions 6speed . I'm sure they will be very helpful to all who do this mod.

We appreciate your contribution to the "Family".

[Carnut]

Thanks for the install info.

I will be doing this next weekend, so your thread is great timing.

[Alloy Dave]

I polished mine today. No need to post pics, a mirror image of what you posted.

Dave

[Carnut]

Mine cleaned up with a cloth rag and a little Windex. Easy deal.

[King Cobra]

What your seeing is flux residue from the weld. Very easy cleanup.

[Alloy Dave]

I sanded the Ford Racing log with 400 grit, then 1000 grit, then metal polish...gives the lettering logo a bit extra shine.