The Cal-look Lounge

Well as the title says really - I am planning a little "Pre-Cal"/Early Cal Look motor for next summer and I have some parts and ideas coming together but the "grey area" for me is the exhaust system  :-\ I really really want a proper original old skool header - I already have a friend/pin striper readfy to do the sign writing on my left rear fender  ;)

I am really looking for pictures of the old systems & mufflers - I would like to hear from some of our "old skool" friends on here about what they actually used etc but PICTURES are the most important thing  ;D

I look forward to seeing those White Glass Pack Mufflers soon  ;)

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Now this is the picture I was hoping for  ;)

Thanks for all those other pics fabs - it REALLY helps  ;) ;D

glad to help you
 ;)

Find a 40hp header. Glass pack should have a 1 1/2" core, be 18" long and 3" diameter. Placement and tip(s) is up to you. This will give a great sound but not be obnoxiously loud.

Thanks for the tip dude  :)

There's no need to buy a used exhaust system if you don't want to. A bunch of those early systems are still in production here and there.

The Scat header above is a carbon copy of the Thunderbird system. Pertronix bought Thunderbird from founder Ermie Immerso and still produces that exact same exhaust with the bell tip at the end of the glass pack. The header with muffler is part number H4068.

I know for a fact that Ermie's large-flange headers were 1 1/2 because I had one 25 years ago and I have a basically NOS one hanging in my shop (painted white at that!). I also know that it kicks ass even with heater boxes. I had one of those systems with a chrome glasspack on a 1500 single port. That car really scooted. It sounded awesome, too.

Pertronix also still sells the zoom tube for that large-flange header. It's part number H4068. It's chrome, too.

Pertronix also bought Doug Thorley headers. It produces the Bugpipes as part number H4076 and H4076 (all chrome). I do not advise that system, though. It pairs cylinders 1&4 into one pipe and then 2&3 into the other. It kills torque.

All of those systems are correct for at least 1971 (I'm looking at a few in a magazine right now) if not earlier. And all of them are really affordable still.

Here is the Pertronix catalog. As far as I know the Pertronix exhaust parts are still made in the US. 
http://www.pertronix.com/catalogs/pdf/tbird/tbird_2008.pdf (http://www.pertronix.com/catalogs/pdf/tbird/tbird_2008.pdf)

c

This single quiet-pack muffler seems nice (parts #H4065 and #H3920).
Seems to be mounted with a belt on the header  ??? : this would mean it would be pushed under the rear fender and stick on the side of it perfectly. Instead of sticking under the rear bumper like many muffler you can find today.

Those mufflers do tuck rather well. However, since we're talking pre-cal they would be inauthentic. I can't remember the exact date that the quiet pack came into vogue but it was some time later--maybe '74 or even '75 or '76. I have the story that 'introduces' them but I'd have to dig into the archives to find it. And I have a deadline to meet (and it was yesterday).

But yeah, those are good fitting muffler systems.  Personally, though, I would just cut any of them apart and weld them back together to fit perfectly. 

They should consider selling a dual quiet-pack. The only thing I personally dislike is the chromed and flared tip. But I guess it could be easy to fix.

Cool thanks for the info dude  :)

More old pic's would be nice just for inspiration  ;) ;D

My pleasure. If I wasn't so slammed then I could scan a few images from old HVWs. Maybe later on this week I can get a few done.

One thing is for sure: glass packs RULED in the late '60s and early '70s. Somewhere in the stash is even a hide-away system.

Here are some pictures of a system I pieced together...
[attachment=1]
[attachment=2]

The header is a typical four-into-one bought good used at an OCTO swap meet, not sure but I would say it's probably an Empi.

The glasspack is also an Empi, bought it used too at Bill and Steve's. The first owner's wife made him take it back straight away because she hated the noise! ;D
I don't care for the flared tip though, I would rather it had a tip similar to an S&S.

Phil's headers, circa 1968. Dual boom-megaphones, super loud, back fires, and shot flames (but only on Sunday mornings near church services)... La Habra residents hated this car!

That car is sooooo boss!

Here's my muffler that I knocked up using a Cherry Bomb and an old stinger....

(http://i33.photobucket.com/albums/d54/1967vw/67Bug1.jpg)

Carol's not grungy, she's bitchin'.  :P

¿que?

The thing about saying the wrong words is that A, I don't notice it and B, sometimes orange water gibbon bucket and plastic.

I work for PerTronix as the Director of R&D for the Exhaust Division. We bought Ermie Immerso Enterprises (Thunderbird Headers) a bit over 12 years ago when Ermie decided to retire. He passed on in 2004. We never really pushed the Thunderbird line after acquisition to the retail market. As Ermie had done, we do a lot of this product as Private Label. We have recently started to discontinue most of the Thunderbird Line and are selling a majority of it on Ebay. Although we still do quite a bit of Private label.
  The H4068 that was mentioned above is a 1 1/2" primary with a 2" inlet Glaspack in black, but we are sold out of them. We do have a few left in Ceramic Coated
The Zoom Tube mentioned is actually part #H3903 and we do have some of those left.

As for Doug Thorley Headers - we did NOT buy that company. It gets a little confusing, so bear with me. Doug's original company was called Headers by Doug and then he started using Doug's Headers. Eventually it became Doug Thorley Headers, but that was about the time that he got divorced and his wife Betty got the company. Although he did do some R&D and assist her with the business over the years (and Jerry Jardine did some design work for her as well) Doug had his own company called Doug's Headers. When Betty passed away, here partner sold the company to Summit Industries (NOT Summit Racing) in Corona CA who also owned Jardine (Since sold to SuperTrapp). They never did any VW stuff as Thorley that i am aware of and certainly don't now. When Doug decided to retire about 8 years ago, We bought The Original Doug's Headers. The H4076 and H4077 listed above (Bugpipes) are NOT the Doug version, but Ermie had that same design as well and so those are a Thunderbird product built in the Thunderbird fixtures - the Doug's ones were destroyed long ago, before we bought the company. But either way, those have been discontinued as well. 

Just thought I'd fill in the blanks here  ;D In the long run what will happen to the Thunderbird name and product line? Hard to say. It may go away or we may resurrect it. But with so much VW stuff being produced off shore these days and a smaller market than the heyday of the 1970's it is difficult to compete and make a reasonable profit. As they say - stay tuned.

Just for fun, here is what the Thunderbird 1 3/8" header and single Quiet Muffler look like today on my 66 Bug. This is the H4065 that Nico was talking about. And it is a hose clamp that goes through the tab on the muffler and then around the #2 tube to support it. The early (1970's) version had a HUGE hose clamp that went around the entire muffler and the header tube.
And Chris, I am pretty sure the Quiet Packs first came out in 1975, I was working at Auto Haus then and I remember when we first got them, so my fuzzy memory says '75
(http://i305.photobucket.com/albums/nn203/hotroddon/IMG_1816.jpg)

(http://i305.photobucket.com/albums/nn203/hotroddon/IMG_1815.jpg)

Guess I should have cleaned the chrome tip, but i drove through some rain on the weekend.  ;D

You could also make your own home made "early header", like my friend's one, a cheap Kadron mixed with a Stinger, white painted and it's done  ;D

(http://static.skynetblogs.be/media/98123/669153227.jpg)

Does anyone know WHO Anchor Muffler was and where they were located?

here  ;D ;D

Wasn't sure if that was the same place, as I asked in there a while back if they used to do VW headers and no one seemed to know anything. I understand it has changed hands over the years though.

Thanks John, it looks like Pat sold to a guy named Carlos in the past few years. Like I posted above, the guy working there knew nothing of the VW history

Thanks for the clarification, Don. So you work with Don Lindfors? Super guy he is.

My memory is equally fuzzy about the exact year of the QP but the more I think about it the more I think your '75 recollection is correct. I'm going away for a day or two but I'll dig into the HVWs binders again and pin down what month those appeared in adverts.

I remember the story that Ron Fleming did about installing duals on a car--I think that may have been '76. Was that the issue with the back of the Manx buggy with the dual quiets on it? Wasn't that the same buggy that Jim Tschaan (Kymco and later EMPI) owned for a brief period? I do know that he had a blistering fast yellow buggy that he spun in some intersection--maybe Harbor and Victoria.

Thanks for the clarification, Don. So you work with Don Lindfors? Super guy he is.

Chris,  the guy writing comments is Don Lindfors.............................

Chris - Dat be Me, my friend - I am one and the same (http://www.freesmileys.org/smileys/smiley-laughing001.gif) (http://www.freesmileys.org/smileys.php)

Opps, John already clarified that.  ;)

Very nice, I like the way the muffler is sitting under the car. And the tip isn't too much flared as well. Thnaks for the infos and pics  ;)

I sent you a private message Don.

That would be consistent with my memory. The first one I saw was on a friends black '67. This was the car that sent me on my road to ruin!  ;D

Anyway he had the car 3-4 years before I bought my '67 in '77 or '78 and I never remember it running anything but a QP.

Jesus! How many Dyno Dons can one forum have?!?!?! I was traveling so I didn't get the reply to this post until I saw you post the Blair Anglia (good lord, ANOTHER DON!).

No, there is only one of ME!  :D

does anyone know which header this is ?
the big flange looks rare....
[attachment=1]

Looks like a run-of-the-mill Thunderbird header and QP, to me.

welll.. got this thing here... 35mm pipes (1 3/8")

on header is a sticker "made in mexico"

on the muffler "made in hong kong"

no thunderbird sign at all...

flange on header is 2 1/2" (63,5mm)
flange on muffler is 2" (52mm)

I guess what I should have said was 'Thunderbird style.'  Lol. 

Let see some more WHITE MUFFLERS  ;)

I'm gonna bump an old thread of mine........

And a small update..... I brought a NOS/boxed  Ermie Immerso Enterprises header and Glass pack muffler a while back - The sales invoice shows it was sold back in 1995

Unfortunetly I was sold it as a 40hp system BUT the header was for later 13/1600  ::) so after some cutting/grinding/welding I got it to work on my 1200....... I then set about making some metal "fresh air" pipes for the heatexchangers...... sounds easy huh  ::)

The left one for 3&4 is pretty straight forward only taking 2 pieces weled together but the right one for 1&2 is a nighmare! It took 5 pieces pie cut and twisted to get it to work and look right..... The worst part is though after approx 8hrs work NO ONE will ever see it  ::) :D :)

I have wrapped the header/fresh air pipes/joints with some HIGH QUALITY white exhaust wrap and the Glass pack muffler is painted in MATT white with a nice 70's style chrome flared tip  ;)

Pic's to follow soon  :)