Fabing my own Muffler!

[cburke23]

Well, I was thinking of how I could do this and I was watching the power block on Spike TV. On the show Muscle car they show you how to make a glass pack type muffler. I needed one for my Honda project I’ve been building and needed it to be really small so I did one my self! Not sure how it sounds yet because the motor is not in the car! If everything works out I will do this for my 2G as well. Now I don't think I am saving any real money by doing this but I like to build things!

When done I will get some mandrel bent pipe and finish off the axle back. Also I will run a turn down tip and paint it black.

Started with a 2 1/2 pipe and a drill press

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Cut out my 4" outer pipe

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This is one of 2 end plates I have to cut out.

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Like a glove!

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Here it is so far! I still need to pick up my steel wool and fiberglass but I will get that tonight.

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I'll get some better pics because the pic makes it look so big and it IS not!

 

[toofast82]

Interesting
Looks good so far!

 

[Eeeeky]

looking great!! Hopefully it wont sound like a fart cannon

 

[LiquidX]

Would there be any benefit to putting in a type of fine mesh to cover the holes to prevent packing from falling out? Other than that looks interesting, you'll need to post sound clips with this muffler on both the Honda and the DSM.

 

[daren_p]

Looks like a great DIY project, as long as your not expecting a huge reduction is sound? Hard to tell from the pics, but it appears the muffler you made is only about 5" or 6" long? If so, I doubt you'll get much in sound reduction. If your wanting a quiter muffler, I would imagine it will have to be much longer &/or a larger diameter to pack in more sound deadning material.

 

[saturnshadow]

Also you could run some SS mesh right over the 2.5 pipe then over that the fiberglass packing. it will take some of the heat out and make the fiberglass packing last longer.
I do this will all the Harley mufflers i deal with.

 

[cburke23]

Also you could run some SS mesh right over the 2.5 pipe then over that the fiberglass packing. it will take some of the heat out and make the fiberglass packing last longer.
I do this will all the Harley mufflers i deal with.

I was going to use steel wool before the fiberglass. Where could I get some SS mesh from?

Looks like a great DIY project, as long as your not expecting a huge reduction is sound? Hard to tell from the pics, but it appears the muffler you made is only about 5" or 6" long? If so, I doubt you'll get much in sound reduction. If your wanting a quiter muffler, I would imagine it will have to be much longer &/or a larger diameter to pack in more sound deadning material.

Yeah it is pretty small. See it's an 89 hb, I did not want to run the exhaust across the back like the factory so I will be mounting this on the pass side up where you can't really see it. I am guess there will not be much in the sound reduction but we will see, it's only a 1.5. I will deff do some sound clips when its done!

Would there be any benefit to putting in a type of fine mesh to cover the holes to prevent packing from falling out? Other than that looks interesting, you'll need to post sound clips with this muffler on both the Honda and the DSM.

That is what the steel wool is for, not sure how it will work

 

[saturnshadow]

This is what i used for my harley
Two Brothers Racing Stainless Steel Wool Wrap For Muffler Repack - BikeBandit.com

 

[RipperXX]

Thats going to be loud as hell, mark my words. One key to a muffler doing it's job is volume....that doesn't look to have much.



But cool that you made it non the less, looks like you did a decent job. Post a vid so we can hear it once installed?

 

[saturnshadow]

to bad it is not a 3" ID. i have heard that adding the spiral flow insert inside a glasspack makes a big difference.

 

[Rob10_99]

You should use a punch and bend in the leading edges of all those circles, that should deflect waves better into the SS mesh. Just like a glass pack you can put it on either way.

This is pretty sweet if your an audi fan, http://images.google.com/imgres?imgurl=http://lh6.ggpht.com/_3GLiPiRoKP8/RfdnvGnez6I/AAAAAAAAAH4/JldJ1zfTzIQ/C:%255CDocuments%2Band%2BSettings%255CHerman%255CMy%2BDocuments%255CMy%2BPictures%255CVanagon%2Bsyncro%255CDSCF2693.JPG&imgrefurl=http://picasaweb.google.com/lh/photo/QqSv06GhXNcJ0R-EdHd-gg&usg=__zgsdRfyxIUZBx6fCO4ezxhKGDoE=&h=1512&w=2016&sz=247&hl=en&start=8&um=1&itbs=1&tbnid=oKRcNiUI8QwphM:&tbnh=113&tbnw=150&prev=/images%3Fq%3Dhome%2Bmade%2Bmuffler%26um%3D1%26hl%3Den%26safe%3Doff%26sa%3DN%26tbs%3Disch:1

 

[Lofty]

This is really great, but you should TIG it so it looks real boss! Pack the crap out of that, with as much as you can, If you pack a whole lot I bet you will hear a difference.

 

[Kid4g63]

I saw the same show. Looking good so far.

 

[cburke23]

Thanks guys, I got the steel wool yesterday and the fiberglass, so I should be able to finish it up. Tiging is not an option for me, don't have one . I was thinking about doing that to the fins but was not sure how. I guess I could use a hammer and maybe a flat head.............

 

[slowgsr]

I was going to do this myself, except for my 4" aluminum exhaust, I wanted to build an aluminum muffler. However, I would have done it slightly different.

I would have drilled the holes much smaller, ever seen the 'perforated' sheets guys use when they build mufflers? They buy the sheets then roll them round, as well as the case. I just can't find any perforated sheets in aluminum. I didn't want to do the vband option either and use a stainless race muffler, since vbands are expensive, as well as another few bucks for a premade muffler. It would be half the price to do it myself, and it would be much lighter.

Looks good, Try to get up some sound clips!

 

[cburke23]

I am going to hammer the holes a little to get the fins down on the inside. I think that will help with the sound. This is the first one I have ever done so I will lean as I go! Should have it all done tomorrow.

 

[cburke23]

Got the muffler DONE! Just need to paint it but that will have to wait untill I get the axle back done.

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I didn't get pics of the fiberglass going on, but it goes around the steel.

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Here you can see how small it is! Size 10!

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Where is should go!

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[timmy]

Wow, that does look great!

 

[LiquidX]

Was the packing still loose when you put it in or did you really jam it all in? All-in-all we need AUDIO!!!!

 

[cburke23]

Yeah I had to jam it in there and even had some sticking out that I had to trim.
I am waiting on Mounts and getting my flywheel turned so I can get the motor in. The I will get it all hooked up. May be a few more months..............

 

[sonik619]

Yeah I had to jam it in there and even had some sticking out that I had to trim.
I am waiting on Mounts and getting my flywheel turned so I can get the motor in. The I will get it all hooked up. May be a few more months..............

aww I was ready for those sound clips.

 

[gixrman]

you can get S/S wool, perfurated sheet, fiberglass packing from mcmaster-carr. I was planning on doing something similar after watching that episode too. mine will be a S/S center and aluminum riveted outer sheel.

 

[supravw]

You have way more patience then me, I saw that same show and thought someone would have to be insane to put that much time into building a muffler you could buy for 50 bucks.

 

[cburke23]

You have way more patience then me, I saw that same show and thought someone would have to be insane to put that much time into building a muffler you could buy for 50 bucks.

I know, but I only spent like $10.00 because I had most of the stuff I needed. All together I am sure it could be done in about 2hrs.

 

[TurboTerror99]

That's got to be one of the craziest things I've seen. I commend your efforts, man! It looks surprisingly good too!