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Rear muffler on the 535i was rotted out. Purchased Bosal rear muffler unit from carparts.com ($189) to replace. Here's the net net of the process.
- Bosal claims clamp on fit. Well, sorta. It clamps on to the Bosal front resonator unit. It does NOT clamp on to the existing BMW resonator.
- Since my resonator unit was fine, this meant that I now had to fabricate the connection between the existing system and the new bosal muffler.
- There is NO WAY you can do this with normal shop tools Clamps, etc.
- In the end, I had to custom contruct the connnection. This involved using stock metal, a jig, and a wire feed TIG welder. NOT EASY. Thanks to my younger brother who's a wiz with this sort of stuff, it all worked out just fine.
- Look and sound is stock. Actually, has a little throaty sound out the pipe. Maybe my existing BMW muffler was so rotted, it had lost all tone...
Bottom line - if you plan to DIY, buy both the front and rear section from Bosal, otherwise, plan to hire your local muffler shop. Or, be prepared for some pretty significant welding and fabrication work.
Remember, this is a 535i. None, some or all of this may apply to a 525 installation.
Jeff
90 535iM Sharked
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