While we certainly could have installed a modern replacement, such as the Dansk Sport muffler, this project is all about the little details that make it original.
The rest-of-world 911s — including the 1976 Carrera 2.7 — were equipped with the Bischoff 911.025.01 two-in, single-out mufflers during 1974-1976 (and possibly beyond). The North American Carrera models were equipped with the same muffler in 1974, but starting in 1975 they switched to a revised design for emissions. This makes having an original muffler here in the States quite rare as not only have most rusted out, but if you ever wanted to find a replacement there would be few options.

Bischoff must have produced these mufflers in mass quantities as the date stamp on the 1976 Carrera 2.7 muffler was May 1974. The muffler was in ok shape under a cursory examination, but once inspected closely there were some signs of rust that had to be taken care of as well as some scrapes to the tip in the past. The repairs were carefully done, taking great pains to preserve the original factory welds as well as the part number and date codes on the bottom. While it would certainly have been much cheaper to just buy and install the best muffler Dansk offered, the goal of this project is authenticity and originality wherever possible.

Update 7/25/2012: Guy White — a UK expert on the Carrera 2.7/3.0 models — noted that the rear valence and rear side skirts shouldn't have texture on them (not to mention the texture was too fine). This was a mistake by our painters that is being corrected as well to be the original flat finish.

The original muffler tip was repaired by welding additional material onto the end which had been ground off and then repainted the correct black finish.

Bischoff 911.025.01 muffler with May 1974 date code and original factory welds for the flange.

Final installation of the muffler gets the Carrera one step closer to firing up.