SeeeeeYa

OK, simple it is. One 11 inch piece of (in this case, YMMV) 12/2 copper wire sourced from that 12/2 Romex. Wind two turns around a gasket hole sized object, a Sharpie marker is perfect. Using the pliars you have been using gently crush the two turns flat. You now have two flat "washers" with a 4 1/2 length of wire between them. Bend to fit flange gasket, bolt it up tight. Done.

By the time the exhaust gets to the mufflers there will never be the 360+ degrees F. even the softest solders need to melt. Further, even without any solder the assembly as shown is mechanically stable and will remain an effective gasket without coming apart. The copper will deform to fill the upper gap and the steel washers will remain captive. However, this was chosen because it was quick and easy. Perhaps a more ideal method would be sheet stock cut to gasket-like dimensions with the side eliminated to create a horn shaped slot aperature, like rpm6500 proposes. Made of a select few thicknesses sound could be individually adjusted with ease. If you recall, or if you look under the rear of the car, you'll notice that the resultant exhaust gas vector is to the rear along the muffler. No hot gasses hit the car, and especially are no where near gasoline. Like I said, it has no downside, it's not an exhaust leak it is an exhaust sound tuning port. Whip up some of those gaskets. My washer/wire gaskets are made in minutes. Remember that the flange junction is subject to a lot of flex therefore materials should be chosen to remain stable despite a missing support face. It is such an interesting sound I like having a reason to start the engine in different places, and to go through the gears different ways. Since this end of the power system will be the last to be modified with aftermarket pieces this will satisfy until then.

Here is the 'hogmeat exhaust-boxer audio tuner-Gasket' I made. This produces an exhaust note that seems little changed from stock, except for new components. Refined, yet edgy with more serious promises. The sound is in context with my polished, lowered just enough, Legacy 2.5GT. A heartbeat restored. Notes: The 12/2 Romex copper wire part is 3 and 13/16 inches long. The washers are 3/8 inch and 'thin.' The slots in washers were first cut with a hacksaw then opened with a Dremmel. The parts were cleaned, swabbed with soldering paste, and soldered together, making sure the wires were seated into the bottom of the slots. This was done on a flat surface to align parts. Holding the assembly with the two washers in the thumb and forefinger of both hands, kind of turn outward while bringing the washers closer together. You can see what you get, a perfect gasket. Install these with the copper wire upward on both sides. This makes a kind of acoustic horn slot facing backwards along the side of the muffler. The results will offend no one, people will turn to see you approach in low speed situations, and follow as you go by, wondering and appreciating. My exhaust is catless with stock (modified internally) cans that are always too quiet. Although early hogmeat mods provided the principle, this 'boxer audio tuner gasket' appeals not only to my ear's need for motor sounds, it is also aesthetically acceptable as well. To me, of course.

HELP! Keyboard stuck or something, Moderator remove this please, except for perhaps the last. Anyway.... Last and final mod to the original hogmeat exhaust was to make a real exhaust piece that elevated the mod to a genuine 'installation.' I took a 3/8 washer and hacksawed a slot nearthy to the center and dremelled it about twice that width. A 3 and 13/16 inch of copper wire from a 12/2 Romex was soldered between two of the washers, the wire soldered into the slots of two washers. Cleaned up the rusty flanges, evenly bent the Wire so to fit the bolts in the flange making sure it covered the upper side of the flange, and bolted it down hard. I can hear the boxer note at almost any speed up to near seventy. I'm happy, my wife is happy, and my ears are happy. Thanks, hogmeat.

After jumping into these muddy waters I've gone through several changes to my hogmeated exhaust. First I just found four thick washers from my collection and after unbolting the mufflers and removing the gaskets I threw them on. Hmmmmmmm, loud. Wife actually slid down in the seat going past one of her clients and hissed 'do not stop! I don't want anyone to know I'm in this car!' Clear enough for me. Second revision was the same thing but with some nice shiny new , thin, washers from Lowe's. Not bad. Later I remembered all that gasket stuff and rust I left there in my haste. So I took a hacksaw blade and ran it back and forth in the hogmeat slot. All kinds of stuff came out..... and the car was once again a little too loud for my honey. Sigh. Third mod to the hogmeat exhaust was......... a wire. I got a piece of Romex 14/2 and took out one of the conductors, stripped it, and formed it to fit between the washers, in effect putting a copper 'O' ring seal across the upper half of the flange. A dab of copper silicone on each end convinced me it would stay. Concensus; boxer sound without redneck overtones somehow. Looking at it it was now apparent why I liked it. It was no longer a LEAK, but a rearward facing exhaust port that tuned the audio output of the engine. I was now actually proud of the sound. Because there was no audio pulse out of the upper side of the flange reverberating off the cabin the sound inside was really different. It sounded like I had a new exhaust system that allowed me to hear the engine better, the boxer rumble modified by load. The connection between my foot and the engine now included my ears, thanks to ol' hogmeat. Autoxing

What the hell, me, too :0 Hogmeat Stage 2 and wife wanted to hide, Stage 1 and she's all fine. Ahh, those marriage compromises keep the mods coming Vindication, thy name is Hogmeat!

Thanks. Jedi, you ARE d'Man!