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A joint system for a dual inlet muffler has been designed which allows the muffler system to be better aligned during assembly. The system uses a slip-fit joint coupled with a ball-and-flair joint. This combination decreases variations in manufacturing and assembly thus, improving tailpipe variability in the vehicle build. The slip-fit/ball-flair joint was compared to conventional inlet systems of flat flanges and flex-couplings. A Variable Simulation Analysis (VSA) audit, finite element analysis of the joint strengths, and variable cost study all showed advantages for the slip-fit/ball-flair system.