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Old 03-11-2009, 03:06 AM   #1
NotSafe OP
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Building a poor mans Muffler and exhaust

So I dont feel like paying 500-800 in a full exhaust so I figured Id give a crack at building a full exhaust system for my DRZ for cheap.. I started off by picking up some
4" Diesel exhaust
1.75 Auto Exhaust
2 1.75 couplers
16 gauge 6"x18" sheet metal
And Exhaust packing




I then cut the 4" exhaust down to 14" long



No was the time to trace the 4" diameter to the sheet metal



I didnt get and pics of some of the setup but I cut out the 4" disk, and then cut a 1.75 hole in the ceter of that, you weld the disk to the coupler and then to the 4" tube




Next was the pain staking moment of measuring and drilling an ass load of 1/4" holes alternating all through the 1.75 tube




After drilling I went and made another disk to fit on to the inner tube and also cut a 1" peice of the 4" tubing and removed 1/4 inch so the 4" tube can fit into the other 4" tube, weld





And there you have it, in the last pick I dont have the inner section into the outer.. Still have more grinding to do to make it look nicer, also have paint and I will be trimming the inner tube alittle more but that will come when I start bending tube for the header and intermidiate tube.. More will come
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NotSafe screwed with this post 03-11-2009 at 03:14 AM
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Old 03-11-2009, 04:14 AM   #2
DRjoe
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looking good.
How did you figure out the tuned length.
You might know this already but just encase you don't. When you pack the silencer wrap wire wool around the perforated pipe before you put the fiber glass in
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Old 03-11-2009, 09:18 AM   #3
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Header tube next?

Looks good. I've always thought that cans are way too expensive as related to materials.

Here, we would just need a spark arrestor added.
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Old 03-11-2009, 11:46 AM   #4
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Quote:
Originally Posted by DRjoe
looking good.
How did you figure out the tuned length.
You might know this already but just encase you don't. When you pack the silencer wrap wire wool around the perforated pipe before you put the fiber glass in
I copied the MRD Exhaust from looking at pics

Ive always just put the fiber glass right on the center tube, why do you add steel wool?
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Old 03-11-2009, 11:48 AM   #5
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Quote:
Originally Posted by groop
Header tube next?

Looks good. I've always thought that cans are way too expensive as related to materials.

Here, we would just need a spark arrestor added.
Header tube next, I maybe have $25 into the can, and the fiber glass is cheap... Im going to work on a drop in spark arrester that will go into the end pipe..
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Old 03-11-2009, 01:03 PM   #6
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the first layer of (stainless) steel wool is to keep the fiberglass pack from blowing out too quickly.
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Old 03-11-2009, 01:14 PM   #7
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so you built it on the cheap, but are you going to dyno it to prove it works, or you just wanted sound?
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Old 03-11-2009, 01:54 PM   #8
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Quote:
Originally Posted by tedder
so you built it on the cheap, but are you going to dyno it to prove it works, or you just wanted sound?
Anything will help the motor out compared to the stock exhaust on the DRZ.. Im just a cheap basterd and enjoy building things rather then typing credit card numbers in
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Old 03-11-2009, 01:57 PM   #9
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Nice Job!
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Old 03-11-2009, 02:11 PM   #10
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Quote:
Originally Posted by NotSafe
Anything will help the motor out compared to the stock exhaust on the DRZ.. Im just a cheap basterd and enjoy building things rather then typing credit card numbers in
No, I appreciate the DIY ethic, I'm just saying it may not gain you much.
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Old 03-11-2009, 02:21 PM   #11
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How much does that muffler weigh?
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Old 03-11-2009, 03:24 PM   #12
54FordCoupe
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Quote:
Originally Posted by NotSafe
Header tube next, I maybe have $25 into the can, and the fiber glass is cheap... Im going to work on a drop in spark arrester that will go into the end pipe..
Looks good these are the kinds of threads i like to read. I just posted a thread in "garage" about a spark arrestor insert. How are you gonna do it? what Mfg. are you going with? i have a 1.5" inner diameter pipe im trying to add an arrestor to but its hard finding actually spec's/sizes on universal spark arrestors (mesh cones) ... thanks for any help BB
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Old 03-11-2009, 04:24 PM   #13
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Quote:
Originally Posted by 54FordCoupe
Looks good these are the kinds of threads i like to read. I just posted a thread in "garage" about a spark arrestor insert. How are you gonna do it? what Mfg. are you going with? i have a 1.5" inner diameter pipe im trying to add an arrestor to but its hard finding actually spec's/sizes on universal spark arrestors (mesh cones) ... thanks for any help BB
I plan on making a mesh insert to be installed in the rear that will be held in by a bolt for easy removal
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Old 03-12-2009, 01:26 AM   #14
motu
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I made a couple of mufflers for my XLV750 several years ago (pre digital camera).I used the Helmholtz design in one of A Graham Bell's books (hint to anyone with a photo copier) .I photocopied it and blew it up until it was the size I needed,then made a couple.It was just a couple of cones,one inside the other,and a couple of closed Helmholtz chambers.To be even cheaper than NotSafe,I used an old driveshaft for the tubing.

I dynoed the bike before and after,with no change in hp.
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Old 03-12-2009, 01:40 AM   #15
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Funny you should post this, as I'm about to embark on a similar project.

My goal is weight savings without making it any louder, though.
I've decided to use Aluminum Flashing for that reason--super light and thin (the muffler is tucked in behind the GIVI racks, so it doesn't have to be strong).

I plan to use all the same internals, just replacing steel parts with aluminum.

You can see people making fun of me here:
http://weldingweb.com/showthread.php?t=28473
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