Hadn't planned on doing this until I modded the front half of the exhaust system first but , seeing as I was going to take the original muffler off to ease fitment of my custom towbar ,I thought I might as well do the Berklee (BSO655)mod while I'm under the car. Couple of pointers for anyone wanting to have a go.The biggest one ,which may have been mentioned somewhere in this forum but I didn't pickup on :doh:,is that the exhaust pipe narrows dramatically (60to50mm)just before the last flange in front of the box. So simply cutting the old box off and welding the pipe back onto the new one(as i thought) aint gonna work as the Berklee is much bigger , you will need to cut just before the flange were the pipe is still 60mm and then use a 63mm(2.5inch) 45 degree mandrel bend to complete the union.The 63mm fits nicely over the 380 pipe and inside the Berklee for ease of welding. Firstly, transfer the brackets from the old to the new taking into account the slight difference in box size by measuring there placement from the center of the inlet/outlet holes as this is the common point between the two boxs.Hang box under car and play with the 45 degree pipe to get the "angle of the dangle" just right before welding .Remove the factory oval tip by grinding or drilling the spot welds on the top and bottom then pull the outer off the inner.Cut the inner off and then do the reverse to refit Do this bit after the box is on the car to make sure you get it straight.:thumbsup:

Thats a good write up. Interesting that you say the exhaust narrows 10mm before the flange. I have never looked under the car but seeing as though I have a Berklee, does that mean the exhaust shop would have had to remove that restriction when fitting the muffler??

Thats a good write up. Interesting that you say the exhaust narrows 10mm before the flange. I have never looked under the car but seeing as though I have a Berklee, does that mean the exhaust shop would have had to remove that restriction when fitting the muffler??

Well good question! Have they done the job properly or bodgy? Just have a look underneath and the flange should be gone or possibly replaced with a larger one,which I doubt but you never know!

Hadn't planned on doing this until I modded the front half of the exhaust system first but , seeing as I was going to take the original muffler off to ease fitment of my custom towbar ,I thought I might as well do the Berklee (BSO655)mod while I'm under the car. Couple of pointers for anyone wanting to have a go.The biggest one ,which may have been mentioned somewhere in this forum but I didn't pickup on :doh:,is that the exhaust pipe narrows dramatically (60to50mm)just before the last flange in front of the box. So simply cutting the old box off and welding the pipe back onto the new one(as i thought) aint gonna work as the Berklee is much bigger , you will need to cut just before the flange were the pipe is still 60mm and then use a 63mm(2.5inch) 45 degree mandrel bend to complete the union.The 63mm fits nicely over the 380 pipe and inside the Berklee for ease of welding. Firstly, transfer the brackets from the old to the new taking into account the slight difference in box size by measuring there placement from the center of the inlet/outlet holes as this is the common point between the two boxs.Hang box under car and play with the 45 degree pipe to get the "angle of the dangle" just right before welding .Remove the factory oval tip by grinding or drilling the spot welds on the top and bottom then pull the outer off the inner.Cut the inner off and then do the reverse to refit Do this bit after the box is on the car to make sure you get it straight.:thumbsup:

Hi guys,
the Berklee is an offset pipe right?
I'm toying with the idea of buying this bit of junk and seeing how it goes , but it's a straight through centre pipe, do you think this would reach the flange? looks tight to me

http://www.crazysales.com.au/stainless-steel-epoxy-finished-twin-exhaust-tip-53-cm-car-muffler_p2355.html

any tips?
Cheers
RG