I have a 1985 240GL pre-catalytic converter model and i want to remove the rear muffler (east-west positioned) and replace it with a jap-style cannon muffler for noise and looks. I have never seen this done on a 240 and any info would be great.

The main issue is you really don't have the room for a muffler put in
that way. You can make some good noise and have a nice tip. But, you really
do need to put the muffler in that same orientation. Here is what I did as
an affordable performance setup. I did what one of the earlier posts said.
I got my own muffler and performance tip. Then I had the shop make up the
rest of a welded on system. I've gone through several iterations of this
for my turbo. I tried no muffler, a glasspack, then a Flowmaster Delta 40
2.5 inch., after that I went to a Ultraflow stainless 2.5 muffler. Over the
course of a few years this was my way of finding a nice sound that still
wouldn't be too nasty. My car is a turbo but this same type of system would
work for a regular model and would be louder. At the same time I used these
mufflers I used a Pacesetter Pencil tip. 3.5" fitted to 2.5 pipe.

For a nice loud sound without the buzzing nasty resonance. I recommend using
something like the Ultraflow used with a resonated glasspack type tip.
Use 2.25" pipe. This would be pretty loud without the undesirable resonance
a four cylinder has in that 2-3k rpm range. Hope this helps you.

Dave 82 242ti

First, forget the fuddy duddies on this board. What you want can be done tastefully but with changes. You need the stock turbo muff that any shop should have. Remove the intermediate muffler. Install a nicely made stainless tip not more than 4in. that tucks in neatly under the cars original cutout. Bonzai motorsports makes nice units that weld on. This will be loud enough to piss off the uptights but not the police. The muffler/coffee can tip type units would look totally rediculous hanging under a brick. They look really stupid under tiny fart cars like hondas, yotas,geos, and saturns. Some people don't have good taste when it comes to proportions. I'll email a pic of my car.
--
92 244 lowered, Bilsteins, IPD sways, Unitek cam/header, TSW Revo 18x8's - 94 965 Niiice MONEY PIT! - 76 Datsun 280Z lowered, modified head, cam, headers, intake

personally i'm against "all show, no go." are you looking JUST for noise and looks and that's about it, no performance gain at all?

needs to be a new term for this.

kraut = german car i think
ricer = asian (japanese mostly) car

i guess for volvos, it'd be ... cheeser, as in swedish cheese? hmm i dunno.

the reason you have never seen this done on a 240 is because it's in bad taste. ;)
--
Kenric Tam
1990 Volvo 740 base sedan (B230F)
My Volvo 'Project'

Hello,

Forget the asshole-style mufflers that stupid kids put on their Honda's. Forget anything aftermarket as well. Go to your local Volvo dealer. Pick up the rear muffler intended for a 240 Turbo. Bring it and your brick to the local muffler specialty shop that has a pipe bending machine and a tech who knows what they are doing. Get them to put the muffler on, and make a one-piece welded system for you. At idle up to about 2500 rpm under normal loads, it sounds like any other brick. Give it the goose, and she growls for ya without pissing off your neighbours at 3am. The system works, does not effect fuel economy or burn exhaust valves. Tried and tested for 150,000 km's on my wagon as well.

Good luck and happy bricking!!!

Richard

87 245 DL 346,000 km
82 242 GLT 121,000 km