Anyone ever built a muffler?
 

so heres my agenda. my muffler is VERY restrictive on my turbo LS powered DC2. when i took the muffler off the other day (because i was losing boost at high rpms) i noticed a VERY big difference in spool up and more power across the rev range. anyway....

my restriction is my Apexi World Sport exhaust. now, i dont want to buy anohter exhaust, and i have a welder, so i was thinking about cutting apart my apexi muffler and converting it from a chambered design, to a straight through design.
my plan is to remove all the baffling inside the muffler and weld a pipe with lots of little holes drilled in it from the inlet to the outlet (inside the can of the muffler) and packing muffler packing around it. would this work? do you think i could use some standard 2.5 inch piping to do this? his is the muffler packing im thinking about buying...

http://cgi.ebay.com/ebaymotors/Four-...spagenameZWDVW


i know that it would be much easier to just buy a staright through muffler, but i REALLY like the look of the world sport and i think that fact that i made iit myself would be really cool. gimme some ideas, i might order the packing tomorrow

Re: Anyone ever built a muffler?
 

That should work.Sounds like alot of work but if you want to keep the muffler then might as well.I would just say the ---- a muffler all together and run straight pipe.

Re: Anyone ever built a muffler?
 

why not sell the name brand exhaust, then use the cash to build a bigger exhaust with a summit turbo muffler

Re: Anyone ever built a muffler?
 

---- the way your exhaust can looks.

Re: Anyone ever built a muffler?
 

---- turbo muffler get a summit oval (think dynomax race, basically it's a giant resonator with up to 4" core)

they're not much more.. and are smaller/easier to fit.

Re: Anyone ever built a muffler?
 

thanks for your contibution JD.

what im trying t say is, i LIKE the look of the world sport, its just restictive as all ----. if i can (on the cheap) cut apart and modify it to make it a straight through, i will. also, the reason why i didnt just go out and buy a summit muffler, is they are loud. the last exhaust i built for my last integra was a 3" straight pipe, no cat, res, or muffler, so im trying to get away from the loudness

Re: Anyone ever built a muffler?
 

why don't you just go with a y-pipe and an E-cutout?

Re: Anyone ever built a muffler?
 

you do realize that your planning on building a straight through muffler now... why would the one you buy be any more loud than one you make?

and you realize that a system with no mufflers like you HAD is going to be alot louder than a system that has multiple right?

Re: Anyone ever built a muffler?
 

ok, you dont get it. i really like the way the world sport looks. i dont mind how straight though mufflers sound. so, im going to make my WS muffler into a straight through muffler.

and um, no ----.

Re: Anyone ever built a muffler?
 

You like that it looks restrictive as ----? ???

Dude! Acquire rope or something.

Re: Anyone ever built a muffler?
 

If it's a chambered design muffler, why not get something like the magnaflow s.s. mufflers...has the shape of a chambered muffler, but with a straight through design. The one I had on my car was pretty quiet once the turbo went on again, flowed like a mofo, but still had a decent tone to it. Just weld it in place of the original one instead of hacking stuff up.

Re: Anyone ever built a muffler?
 

Dynomax welded ultraflo is #1 best str8 through muffler for minimal restriction and minimal riceboy buzz. It actually works as a muffler pretty well.

Re: Anyone ever built a muffler?
 

Man I actually did what your talking about With *L* a vance&hines muffler from a gs700 I put on my old accord.

I took a piece of 2" pipe drilled a bunch of holes in it and packed it with insulation like you put in a dirtbike muffler.

I sounded okay for a month or so ten the packing gets all old and crusty then it sounds like a straight pipe.

Re: Anyone ever built a muffler?
 

im gonna use ALOT of steel wool, which should deteriorate like regular insulation

Re: Anyone ever built a muffler?
 

You can buy a WS pass-through design. I just got spanked on another forum for ASSuming, based on your ignorant post, that all the WS muffs are chambered. It's your fault, and now I will hound you across the internets! :7

Re: Anyone ever built a muffler?
 

oh man.... i know that the 3" WS is a straight through, but i dont want to spend $200 on a muffler, i am of course, an HMT OG.

Re: Anyone ever built a muffler?
 

Steel wool is what I recommend. That or lava rock which is sometimes used in mufflers that will see very high temps.

Re: Anyone ever built a muffler?
 

i did mine, look like a shoebox, 3" center/offset, one chamber filled with fiberglass woven.
Total cost 20$, done with 16ga. steel.
I don't know how it sounds, I should install it in march or april
http://i76.photobucket.com/albums/j1...ademuffler.jpg
Attachment 31407Attachment 31408

Re: Anyone ever built a muffler?
 

Looks good man!

Re: Anyone ever built a muffler?
 

Looks better than the World Sport!

Re: Anyone ever built a muffler?
 

Thats sweet man, should flow nice

Re: Anyone ever built a muffler?
 

Why not just use a high flow canister from a motorcycle like a Muzzys or Yoshimura. It's basically a piece of perferated pipe with fiberglass packing around it. Or Y the pipe and run two cans for nice look.

Re: Anyone ever built a muffler?
 

I really can't see it being cheaper for you to make something of the same quality as what is out there.

I have a dynomax super turb (not sure of the name), but it is a great muffler and it might have been $40 to my door.

Re: Anyone ever built a muffler?
 

Fiberglass doesn't always do the trick since forced induction leads to higher egt's.

Re: Anyone ever built a muffler?
 

I prefer the Magnaflow...i picked mine up off Ebay for $50 shipped, great sound and not restrictive.

Re: Anyone ever built a muffler?
 

for homemade mufflers I use a piece of 4" pipe with plates on the ends, cut holes the size your ehaust is. I used a mesh screen and packed them with brillo pads.
Found the random ---- around the house and work to make them.
You can also open it up and strip the guts from the muff you have now
These are SS before the ends are TIGed on works and sounds good
http://www.picturehosting.org/images...ater/muff1.jpg
http://www.picturehosting.org/images...ater/muff2.jpg

Re: Anyone ever built a muffler?
 

Wow, took me several times of reading your first sentence and I still hardly understand it.
Anyhoo, while that muffler design may be nice and quiet it's also restrictive as hell. You have both the surface area of the screen material and the brillo pads obstructing the gas flow. If you don't mind hindering performance its "ok" at best.

Re: Anyone ever built a muffler?
 

just get a JDM ITR muffler. :1

I actually had a magnaflow as well.. worked good but it got very loud over time as the packing wore off..this was on a NA D-Series. Dont think it would get 'loud' on a FI car though... Paint it black if you want to be hip.

Re: Anyone ever built a muffler?
 

I have a friend running this. He's running a 1.8l 8v turbo VW.

oh, link to his project:

http://forums.vwvortex.com/zerothread?id=1788477&page=5

Re: Anyone ever built a muffler?
 

we do them all the time on rotarys because the heat/raw fuel kills anything else. we use perfirated pipe from the exhaust shop and wrap it in stainless steel wool then pack the rest with rock wool (they use this as instalation) they last for ages and help quiet down a ported rotor

Re: Anyone ever built a muffler?
 

You dont pack them tight, you pack in just enough. You can always take the brillo out. The mesh as 5/32" holes. Those ones we use on a 602CID BBF in a boat wet exhaust that breaths 1100+ CFM and havent had a single problem with restriction. We tried about 5 other methods and thats the most effective that we have come up with.

Re: Anyone ever built a muffler?
 

Creativepunka, I'm working on "pre-silencers" for my 12a peripheral port to keep that beast quiet. Any pics of the perforated pipe? Do most muffler shops carry it?

Re: Anyone ever built a muffler?
 

how do you put holes in a pipe?

http://users.rowan.edu/~fusco/images/drillpress.jpg

Re: Anyone ever built a muffler?
 

Yeah, I've been that route. Do you have any idea how long that takes when making two 24" pre-silencers?
Purchasing a piece of already perforated pipe would make that job so much easier.

Re: Anyone ever built a muffler?
 

Go to your local motorcycle dealership and ask for a muzzys silencer re-packing kit. Perf. pipe, and fiberglass packing =$18.00 For the win! Standard silencers are 2" I.D. and 18 inches long. :y

Re: Anyone ever built a muffler?
 

Fiberglass packing usually dies quickly on a rotary. Gotta go with ss or lava rock.

Re: Anyone ever built a muffler?
 

Go for what works. :y

Re: Anyone ever built a muffler?
 

----, chopping up an apexi WS would make me cry. Did you buy the turbo sized muffler, Mine is the straight thru design and has excellent flow.

Re: Anyone ever built a muffler?
 

you can buy "expanded" steel. its predrilled in an alternating hole pattern about 1/8 apart. its sheet metal, so you just have to roll it and weld. on another note, where can I get some rock wool locally? I've read about it (its basically cotton candy in rock form) and it sounds like it can handle heat like a badass.

Re: Anyone ever built a muffler?
 

---- that, you don't need packing to make a muffler.