How To Build your own mufflers w/Pics

[Metal Twister]

After looking at the inner workings of Flowmaster mufflers and doing some research I thought I would take a crack at building my own. I was after something unique that would minimize the scrape factor at the same time I did want to do my part to insure that they were spark proof. Catching the forest on fire while wheeling... Well lets just say it 's not going to be my rig blowing sparks.:thumbsup:

I made a pattern for the housing out of cardboard to insure that my measurements worked correctly. I then made a set of baffles plates with a series of 1" holes in just one side of the baffle plates. Some smaller center separation baffles were made to hold the main baffle plates apart. The same number of holes were placed in the center separator plates but in different patterns. Plenty of Mig spot welds holds it all in position.
http://i52.photobucket.com/albums/g23/metaltwister/stuff026.jpg

http://i52.photobucket.com/albums/g23/metaltwister/stuff025.jpg

I then slid the baffle section into the shell. I added a few more deflection plates in for added sound deadening and tack welded it in from the inside where the baffle plates ends were accessible. I then bent some strips into a L shape and capped off the slop between the shell and end baffle plates.
http://i52.photobucket.com/albums/g23/metaltwister/stuff022.jpg

http://i52.photobucket.com/albums/g23/metaltwister/stuff021.jpg

Then end caps were formed with a 2 1/2" dimple die hole in the lower center. I Pressed a piece of tube with a 2 1/4" ID. through the flared hole and welded the back side solid. Welded the end cap on and repeated the process for the rear of the Muffler.

On a side note: Both mufflers with baffles, heat shields, and end caps used up a 4' x 4' piece of 18ga. Cost was $19.00

[KansasWoody]

lets get some audio of that!

[Metal Twister]

http://i52.photobucket.com/albums/g23/metaltwister/stuff024.jpg

http://i52.photobucket.com/albums/g23/metaltwister/stuff023.jpg

I added a little plate on top for a heat shield only because they will be mounted fairly close to the floor.

I installed them on a model A I have in the shop Last night also running a 350 and they sound great. Real throaty and metallic, deeper than I expected. I think there will be enough back pressure, but time will tell. These will be going on the FSJ when I get to that point. I should add that I bought 2 hand held stainless food strainers at the grocery store to work as spark arrestors.
l Liked them because they were stainless steel reinforced and cup shaped and they measured 2 1/4". They were stripped of the handles and welded to the inside of the outlet tube inside the muffler.

[derf]

Looks interesting. I'd like to hear an audio clip of how they sound.

[Metal Twister]

I wish I had the ability and know how to record it and get it on line? I haven't heard them with tail pipes yet but I'm sure that will even quiet them down more. They sound allot like the flowmaster, maybe a little bit deeper?

[Ristow]

that is really cool.

[KaiserMan]

that is really cool.

X2. That is some serious skill you have!

[Clean RC]

Very Cool... Can I place my order now for one that is 2.5" IN/OUT...:D

[JeepMods]

THIS THREAD IS WORTHLESS WITHOUT AUDIO :D
What about a 6-7" round muffler with a flat plate on top? How much man???

[Metal Twister]

Very Cool... Can I place my order now for one that is 2.5" IN/OUT...:D


The thread title is "How to build your own Mufflers w/pics"

What part of this doesn't make sense to you? LOL :thumbsup: Nope, I'm not in the muffler business, Just playing around. Actually after building these, Flowmaster's seem to be very fairly priced.:D

(http://www.ifsja.org/forums/vb/showthread.php?t=118557)

[Metal Twister]

THIS THREAD IS WORTHLESS WITHOUT AUDIO :D
What about a 6-7" round muffler with a flat plate on top? How much man???

Ruuuuuum, Ruuuuuuuum, Baruuuuuuuuum, rumble, rumble, rumble, Sorry the best I can do!:cool:

[Chief Gunner]

M.T., you never cease to amaze me with your skill. Now we just got to get you to the point where you can mount those bad boys on your heep and get it off road. As always, looks great.

[babywag]

You've got TOO MUCH spare time on your hands...still cool though.

Come on up to O'side, I'll put you to work....I've got BEER:thumbsup:

[Metal Twister]

You've got TOO MUCH spare time on your hands...still cool though.

Come on up to O'side, I'll put you to work....I've got BEER:thumbsup:

That's the hard part.... I dont have the time to do this stuff.:eek: Im just too cheap to go out and buy it. Its a Curse!

[Metal Twister]

M.T., you never cease to amaze me with your skill. Now we just got to get you to the point where you can mount those bad boys on your heep and get it off road. As always, looks great.
Thanx Chief, Body swap scheduled for the weekend April 10. The plan is to start on the morning of the 9th and be on the road by Tuesday evening. So Wheeling Is on the calendar this year. But most likely not going to see the desert flowers.

[jaber]

Great job. Thanks for the pics and write up.

I have a set of rectangle boxes that look home made. This makes me think they might have been.

If you can record vids with your cell phone, I just text them to my e-mail addy and it makes it easy with Photobucket.:thumbsup:

[rocklaurence]

You've got TOO MUCH spare time on your hands...still cool though.

Come on up to O'side, I'll put you to work....I've got BEER:thumbsup:

Yeh! But I like it.:cool:

[Metal Twister]

Great job. Thanks for the pics and write up.

I have a set of rectangle boxes that look home made. This makes me think they might have been.

If you can record vids with your cell phone, I just text them to my e-mail addy and it makes it easy with Photobucket.:thumbsup:

Cell phone? I threw mine in the trash after 20 years of outside sales along with the pager and blackberry. Best thing I have ever done.:D

[JeepMods]

Ruuuuuum, Ruuuuuuuum, Baruuuuuuuuum, rumble, rumble, rumble, Sorry the best I can do!:cool:

Hahaha that was good... I'll take 2 of those... ;)

[JeepMods]

Just went back and looked at your pics... it looks like the two center "ribs" weren't welded to the outer "skin"... Do you foresee a little rattle from not welding those?

[Metal Twister]

Just went back and looked at your pics... it looks like the two center "ribs" weren't welded to the outer "skin"... Do you foresee a little rattle from not welding those?
Ah, very good observation... The two center baffles are actually a about an eighth inch smaller all the way around. They don't even touch the housing. Plus the 18 ga. is pretty stout. But who knows? I also added some additional baffles to deflect the sound in side. By adding the extra baffles it tied everything together. I will look for the pics of that. It might backfire and they might expand on me. :p They sound good but how long they last is a good question and anybody's guess.:drivin:

[FSJ Guy]

That's some nice skill there. Worth a lot more than $19, IMHO.

Loved the "sound clip", BTW. :D

[Metal Twister]

I took these pics of the additional sound baffles. This shows how it all got tied together. Hope this makes since, sometime I wonder if I can still convey a thought?:confused::D

http://i52.photobucket.com/albums/g23/metaltwister/stuff030-1.jpg

http://i52.photobucket.com/albums/g23/metaltwister/stuff029-2.jpg

I have a buddy that does the ceramic coating. Now that I know what they sound like I think I will spend the money saved on not buying flowmasters and use it on Black coating.

[scantar]

Wow. I'm always amazed at the talent on this board. That is quite a piece of work!



My lack of talent never amazes me though...it just gets me into trouble :rolleyes:

[Metal Twister]

Its not really talent... Its just that I am fortunate to have some really cool tools. :D

[mdill]

Ah, very good observation... The two center baffles are actually a about an eighth inch smaller all the way around. They don't even touch the housing. Plus the 18 ga. is pretty stout. But who knows? I also added some additional baffles to deflect the sound in side. By adding the extra baffles it tied everything together. I will look for the pics of that. It might backfire and they might expand on me. :p They sound good but how long they last is a good question and anybody's guess.:drivin:

Mild steel, they won't last long but your not Midas so who cares, drill a small wee hole at the lowest point to allow the moisture to drip out, will help them last a little longer.

Mike D.

[JeepMods]

Mild steel, they won't last long but your not Midas so who cares, drill a small wee hole at the lowest point to allow the moisture to drip out, will help them last a little longer.

Mike D.

I say forget about the hole... just punch the throttle! the flow of the exhaust as well as the forward launch will empty it out pretty quickly :thumbsup:
Too bad he couldn't powder coat the inside... that would help them last a lot longer as well as reduce the heat.

I just paid $100 for 2 New In Box 40 series Mufflers... The Only down side is that they are 2 1/4" inlet/outlet... My buddy is going to try and expand the inlets and outlets to 2 1/2"... These should sound pretty good behind my built motor.

[jMedia]

Its not really talent... Its just that I am fortunate to have some really cool tools. :D

Care to share them? :D

[Metal Twister]

Care to share them? :D

No... Thats how I keep really cool tools.:cool:

[mdill]

I say forget about the hole... just punch the throttle! the flow of the exhaust as well as the forward launch will empty it out pretty quickly :thumbsup:
Too bad he couldn't powder coat the inside... that would help them last a lot longer as well as reduce the heat.

I just paid $100 for 2 New In Box 40 series Mufflers... The Only down side is that they are 2 1/4" inlet/outlet... My buddy is going to try and expand the inlets and outlets to 2 1/2"... These should sound pretty good behind my built motor.

Won't blow out the low spots, and unless the outlet is the lowest point, water will sit, especially when it only gets fired up for a short time or moving around the shop. On full temp long runs the wee hole does not do anything, agreed.

[JeepMods]

No... Thats how I keep really cool tools.:cool:

Now that's funny! Man you have to have a buddy, a girl "friend"... something that has a recorder either on a phone, camera etc... This is like, torture for some of us... You feed us our fix and then take away the high before we could enjoy it... Not cool man,........ Not cool. :(

[JeepMods]

Won't blow out the low spots, and unless the outlet is the lowest point, water will sit, especially when it only gets fired up for a short time or moving around the shop. On full temp long runs the wee hole does not do anything, agreed.
Gotcha...

[jMedia]

No... Thats how I keep really cool tools.:cool:

Understandable. :thumbsup:

[Metal Twister]

Now that's funny! Man you have to have a buddy, a girl "friend"... something that has a recorder either on a phone, camera etc... This is like, torture for some of us... You feed us our fix and then take away the high before we could enjoy it... Not cool man,........ Not cool. :(

Ok, this is how it is... Im in the middle of prepping a K5 frame for the FSJ body swap next month. Before you ask, The K5 was Free, V8, Lifted, Good steering, good axles, Automatic and newer than smog exempt cars in Calif. So a pre smog body (FSJ) is going on the frame. At that time Im going to install the mufflers and I will find some way to record them for you guys. Right now Im way tooooo busy to play Sound man. :banghead: Why cant you just trust my supreme judgement, relaxe in the fact that they Purrrr sweet music, and just accept that they sound really, really, sweet. :confused::D:fsj:

[CutterN55]

Dang I wish I was still in San Diego... I have a feeling I'll be headed back that way pretty soon though. I could learn a lot from your fab work. Looks good man.

[joe]

You've got TOO MUCH spare time on your hands...still cool though.

Agreed but very nice work !

[gas4blood]

Powerblock TV had an episode of MUSCLE CAR a few months ago that showed you how to build your own mufflers. It was pretty cool but this muffler blows thiers out of the water as far as coolness!! :thumbsup:

[Metal Twister]

Well thanks, The local Muffler shop here in town has some cut always of the different mufflers available. The world famous owner and hot rod Guru Ed Hansen gave me some tips on how to get the ultimate throaty tone while keeping it flowing correctly. Ive had my products on Extreme 4x4 but never the car or truck series. Wish I would have see it. Too busy building stuff to watch the tube! :D Ah, Maybe that is why they are saying I have too much time on my hands? Maybe I just use mine a bit more efficiently? :huh: Joking of course!

[mattmopar440]

Ever thought of making a stainless version ???

[Metal Twister]

If they test out to be the perfect Muffler for the application the next set will be stainless. Hope I wont have to do that for a few years though.

[JeepMods]

If I get picked up for orders to San Diego, You might see my Waggy from time to time...

[Metal Twister]

If I get picked up for orders to San Diego, You might see my Waggy from time to time...Sent you a P.M. on the easiest way to get a hold of me...:cool:

[JeepMods]

Got it, thanks!

[FSJ Guy]

Its not really talent... Its just that I am fortunate to have some really cool tools. :D

I suspect it's talent, too. You put those "cool tools" in MY hands and you'd end up with something that looked like an FSJ RAN OVER IT.

It's the craftsman, not the tools.

[Hankrod]

Wow, I'am impressed! I have never seen such a high quality hand
made muffler, as a matter of fact thats the first real hand made muffler I have ever seen. I guess that I should get out more often. Really, I have done a good share of fabricating with metal in many different ways, but have never considered building a muffler. It looks like you are very skilled and are onto a good thing. Like others have said, a audio clip would be great. Good Job! Hankrod

[Badawg]

Thanx Chief, Body swap scheduled for the weekend April 10. The plan is to start on the morning of the 9th and be on the road by Tuesday evening. So Wheeling Is on the calendar this year. But most likely not going to see the desert flowers.

I would like to help, I am in Lakeside... Flowers are already started, I was south of Mexicali last weekend.

[JeepMods]

I suspect it's talent, too. It's the craftsman, not the tools.

Well said my friend... well said!

[Metal Twister]

Thanks for the props guys, Ive been fabricating soooooo long that its really is second nature to me. The mufflers were for my personal rig so I enjoyed it a little more than most projects. Seldom do I get to goof off and make stupid things. I would of been much better off running down and buying a set and throwing them on.

But then I wouldnt get to use my cool tools. :cool: :D and post up bazaar pics, Thanks again.

[Pakistan Jeep Guy]

Hello there.
I know this is an old thread but I just bumped across this.. The work is very impressive and inspirational indeed. I hope to get down to doing this for my Cherokee soon.. Thanks. I will search and see more of your work now.
Ehsan

[Metal Twister]

So this morning I take my little mufflers to Ed Hansons Exhaust shop and guess what he has... Yep a differential flow meter. Well I had to find out how it flowed and I must admit I was very curious. They pulled a 4 chamber Flowmaster off the shelf and put it on the pedestal and flipped the switch. The green liquid went up to 5.5 inches of water. Then I threw mine on, to my surprise it read 6 then settled down to 5.5. Perfect... Flows as well as the flowmaster and quieter. http://expeditionportal.com/forum/images/smilies/victory.gifhttp://expeditionportal.com/forum/images/smilies/smiley_drive.gifhttp://expeditionportal.com/forum/images/smilies/wings.gif I will go back next week with camera in hand to document the readings compared to the flowmaster. I will post up the proof for you who doubt.:D

[jMedia]

So this morning I take my little mufflers to Ed Hansons Exhaust shop and guess what he has... Yep a differential flow meter. Well I had to find out how it flowed and I must admit I was very curious. They pulled a 4 chamber Flowmaster off the shelf and put it on the pedestal and flipped the switch. The green liquid went up to 5.5 inches of water. Then I threw mine on, to my surprise it read 6 then settled down to 5.5. Perfect... Flows as well as the flowmaster and quieter. http://expeditionportal.com/forum/images/smilies/victory.gifhttp://expeditionportal.com/forum/images/smilies/smiley_drive.gifhttp://expeditionportal.com/forum/images/smilies/wings.gif I will go back next week with camera in hand to document the readings compared to the flowmaster. I will post up the proof for you who doubt.:D

Thats purely awesome. If you ever need an extra hand in SD, I'm always in the mood to help out and learn :thumbsup:

[mdill]

Everyone needs a Hobby !

Thanks for the props guys, Ive been fabricating soooooo long that its really is second nature to me. The mufflers were for my personal rig so I enjoyed it a little more than most projects. Seldom do I get to goof off and make stupid things. I would of been much better off running down and buying a set and throwing them on.

But then I wouldnt get to use my cool tools. :cool: :D and post up bazaar pics, Thanks again.

[JBEES]

Wow those look nice! I was wondering if they would be bullit proof made out of stainles. Also how did you bend the outer skin. I have a metal bender & shear combo but no roll or brake. Just curious because seems like a big savings. And I might give it a try. Hope mine will come out as nice as them, what a great job.
JB:D

[Metal Twister]

The three tools used less the welder were my small roller, My shear up against the wall in the messy room shot, and one of my hole punches of the turret punch.
http://i52.photobucket.com/albums/g23/metaltwister/Bengels%20shop/Shop%20Tools/stuff032.jpg

http://i52.photobucket.com/albums/g23/metaltwister/Bengels%20shop/Shop%20Tools/stuff033.jpg

http://i52.photobucket.com/albums/g23/metaltwister/Bengels%20shop/Shop%20Tools/stuff031.jpg

[JBEES]

What a nice metal work shop, I'm jealous. I am not doing to well the only tool I have that is in that picture that works well is the t-bar square. If i had your mad skills I might go purchase some better stuff. Thank you for the pic's and I think I will try using the old black pipe method for bending.
If that don't work you should make some extra sets I'm sure they would find some homes. Thank's
JBEES:fsj:

[Pakistan Jeep Guy]

The three tools used less the welder were my small roller, My shear up against the wall in the messy room shot, and one of my hole punches of the turret punch.
http://i52.photobucket.com/albums/g23/metaltwister/Bengels%20shop/Shop%20Tools/stuff032.jpg

http://i52.photobucket.com/albums/g23/metaltwister/Bengels%20shop/Shop%20Tools/stuff033.jpg

http://i52.photobucket.com/albums/g23/metaltwister/Bengels%20shop/Shop%20Tools/stuff031.jpg

Nice shop indeed. I wish I had those tools at my shop . :).. I am jealous as well. :).. I would love to see pictures of you making the muffler the next time you do make one. This is awesome stuff indeed. :)
Ehsan

[Metal Twister]

Thank you... This is how I make my living so dont be too jealous of the tools. To be honest I dont know if I will ever make another set.:D But if I do I will take better build shots for you. Hopefully I will never have to build another set. LOL :thumbsup:

[JeepMods]

Hopefully I will never have to build another set.
:noevil: :grumble: :thumbsdown:. So.... you tease us, please us and now you leave us hanging? :huh:. You have to build another one... :thumbsup:
I vote for one more, made from SS and more detailed pics... :cool: I say dontations! I can toss in $10, Lets get him the material for one last detailed and documented SS muffler build.

Who else thinks he should build another one? :D

[Metal Twister]

Wow... There mufflers guys...:confused: Nothing cool, Just mufflers!

I now have a set, why would I build more? Believe me I do have better things to do. But thanks for the encouragement.:thumbsup:

[JeepMods]

:mad:
So sad man... So sad... A skilled craftsman is art in motion, once captured, his legacy is forever influential to those that have dreams... I think I have lost my dreams... lol
Either way man, your skills and products are kickarse to say the least! :thumbsup:

[JeepMods]

I now have a set, why would I build more? Believe me I do have better things to do. But thanks for the encouragement.:thumbsup:

Wait, I will have to argue the above statement... You built two already, I know you have more free time to play muffler build... lol :D

[Metal Twister]

http://i52.photobucket.com/albums/g23/metaltwister/shop071.jpg

http://i52.photobucket.com/albums/g23/metaltwister/shop070.jpg

Ive got quite enough to keep me busy thanks... this dosnt include what I push outside to make room to work inside.

Promise next time I build a muffler I will take better pics.

[Gambler68]

http://i52.photobucket.com/albums/g23/metaltwister/shop071.jpg

http://i52.photobucket.com/albums/g23/metaltwister/shop070.jpg

Ive got quite enough to keep me busy thanks... this dosnt include what I push outside to make room to work inside.

Promise next time I build a muffler I will take better pics.

omg :eek: :thumbsup:

[AlsChopShop]

wow, very nice work! i wish i had 1/10th of that kind of talent!

Al

[JeepMods]

:eek: Ohhhhhhh..... Very nice man!!!

[Metal Twister]

Keep telling you guys... Its the tools.;)

[Pakistan Jeep Guy]

Thank you for the Inspiration. Although not as clean as yours, I got one built here. IT turned out pretty nice and works great as well on the Jeep. :).
http://ijc.com.pk/frontpage/muffler/img_3946.jpg
http://ijc.com.pk/frontpage/muffler/img_3974.jpg
http://ijc.com.pk/frontpage/muffler/img_3975.jpg
http://ijc.com.pk/frontpage/muffler/img_3976.jpg
http://ijc.com.pk/frontpage/muffler/img_3977.jpg
http://ijc.com.pk/frontpage/muffler/img_3981.jpg
Thanks again
Ehsan

[Metal Twister]

http://i52.photobucket.com/albums/g23/metaltwister/SCRAM/PROFSheriffHL.gifhttp://i52.photobucket.com/albums/g23/metaltwister/SCRAM/PROFSheriffHL.gifhttp://i52.photobucket.com/albums/g23/metaltwister/SCRAM/PROFSheriffHL.gifhttp://i52.photobucket.com/albums/g23/metaltwister/SCRAM/PROFSheriffHL.gif

Great job! Glad to see someone else stepping out of the box.... :thumbsup::D:D:D:D:D:D:D:D:D:D:D:thumbsup: I like it allot and thanks for posting it up!

[JeepMods]

Nice Job Pakistan Jeep Guy! Welding with a tourch :eek: ... I haven't seen that in a long time... GREAT JOB!

I do have a question though,.... Do you ever burn your toes? I wear boots and I still burn my toes/feet from time to time :confused:.


Edit:

We need pics with it on your Jeep ;)

[zseese]

those look a lot fancier than the homemade glasspacks I'm used to making

[Chief Gunner]

I have had a few opportunities to watch MT work. I have to say he blows my mind often to his abilities and skill. This is a prime example of what I am talking about. These mufflers are simply pimp and the average guy wishes he could do something like that, but to MT, they are just simply another little time killer. Just wait and see what he does next.:)