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Switch from 3.5 varex muffler to 4 inch varex muffler

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Old Nov 16, 2024 | 12:02 AM
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wiseguy9's Avatar
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Switch from 3.5 varex muffler to 4 inch varex muffler

I got a couple questions I want to bounce off the members here.

I have an evo 9, currently makes 567 whp on e85.

Current exhaust setup:

CB ported fp manifold
CB ported bb fp black mhi housing
artec 3.5” o2 housing
artec 3.5” down pipe
catco 3.5” cat (flows like 970 Cfm)
custom 3.5” cat back to a 3.5” varex electronic muffler.

I want to change to a 4” varex muffler. Current one is going out after 10+ years, when I close the valve it makes clicking noises as if it keeps trying to close the valve. Also, since the valve is in the middle I don’t have a true 3.5” flow.

so:

1) would the 4” varex muffler fit, as it is an oval design and much bigger than current 3.5 canister design I have.

2) would I be able to fit it flush with vehicle instead of an angle? This would require a type of s curve I think.

3) would you use this a v band adapter like https://exhaustreducer.com/products/4-id-to-3-5-id-exhaust-v-band-reducer-adapter-flange-kit-t304-stainless-steel?variant=44904155939042&currency=USD&utm_medi um=product_sync&utm_source=google&utm_content=sag_ organic&utm_campaign=sag_organic&gad_source=1&gbra id=0AAAAA9cxcFgz72oa9jIyNG3JhZZ0LGNx8&gclid=EAIaIQ obChMIwr6hoLDgiQMViT1ECB3O4RNWEAQYASABEgIuHvD_BwE

or

https://www.magnaflow.com/products/10765-magnaflow-35-x-4in-performance-exhaust-pipe-adapter-10765 and then weld v bands to it?

4) my fab shop is pretty capable but should I buy the “s” section in 3.5” ss and what should I buy?

thank you!
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