I've been looking around at aftermarket mufflers lately, and I got to wondering... how dificult would it be to make my own mufflers? I want a pair that will fit under the car, right about under the driver/passenger seats for a custom exhaust I plan to do, so space is tight.

Can it be done, and is it worth the effort? I have some experience with welding and basic metal working, so I think I can handle that part of it.

Anyone here made their own mufflers before?

 

IT wouldnt be to hard to make with your skills. It would just take some trial and error to get the sound right. What where you thinking something flat like on a nascar?

 

I have made 7 sets of mufflers,and a couple different types. i make mine out of stainless steel.

 

that was the first set i made. ive got alot better sinse i made those for my 84z28 last year.

 

Yea, the idea behind it was to make some really thin mufflers, so I'd have some room to fit two of them.

How difficult do you guys think it would be to make a 2 inlet/2 outlet muffler?

 

Start to finish it took me about 2-3hrs (and a few cold frostys ) to make mine. I put a divider in mine since the tubes flow opposite direction (doubt it was really needed though). The casing is 3.5"h x 11"w x 20"d (not exact sizes but close).



It's quieter than it was but still, louder than I want so.. maybe 3 is the magic number...

 

That looks like a dual in-dual out glasspack... that what that is?

 

Basically.... yea. I use perforated metal for my core instead of baffled metal though for a smooter flow. I didn't make the casing height as high as I should have though so, aside from having lost the annoying bass tone I had with the bullets at the bumper, it's only slightly more quiet. The next one I make will have about a 4-4.5" high case by it's current 20" width to allow for dampening material to acually wrap the perforated tube. I also packed the acoustical glass in to tight which make it less effective for dampening noise.
Even with the shortcomings of what I was aiming for (mainly my fault with design), the only cost involved is my time and wire burnt up (as far as making the muffler is involved). I can get sheet for free and perf. metal is $4/sqft which, I already had.

 

That gives me a little idea.... hmm.... whats inside of a Cherry Bomb? Is it actual fibreglass like you used in the muffler above?

 

Not certain, I've never owned a cherry bomb or known anyone who has but, I'd assume that's basically all they have in them. I preferr to use r-13 acoustical fiberglass in the mufflers I make. It's a little more dense and keeps the outer casing fairly cool (as well as can be expected anywyas).

 

What is it that usually makes glasspacks pop? Is it the 'glass, or the perforations, or is it just because they are straight-through designs?

 

its the strait- through design. a car with strait pipes and no muflers will do the same thing.

 

I don't know if the straight through design is to blame or not (I'm no engineer, or extremely smart, by any means). If I were to just guess, I'd say it may be a mix of the normal baffle design with the fact there isn't alot of dampening material in them since the case is barely larger than the core leaving very little room for dampening material. Neither of my cars pop when revving down.
I have one of the 'old' mufflers from the 'bird on my camaro in the cat. location, no problems yet (both cars are 5 speed).
Though it's been a long time ago, the flowmaster I had on my 'bird did pop annoyingly whenever it could. Same problem on my old 84 lg4 camaro too (same muffler).