I've been giving this some serious thought lately, mostly to save some money for other more pressing matters. I have some access to a muffler shop (I get my exhaust done for the cost of pipe) and I like creating all of my own parts (90% of the 94 is grinder fabbed). So here's the idea: Make a 3.5" tall x 10" deep x 14" wide box, weld in some baffles with some expanded steel and some fiberglass. I checked out how Flowmaster makes their mufflers, I like it but I wouldn't use that much baffling.

What thickness of steel would I need for material longevity? I'm mostly worried about it blowing out or sounding like a bag of ***, and since I'm on a budget I really can't go buy a new crossflow.

 

Do a search. A guy by the name of deadbird on this board builds his own. Ask him, he can probably answer any questions you might have.