Here are some pictures of the scratch built muffler I built for my G260. The original specs for the muffler is by Michael Tyson. He can be contacted at firstname.lastname@example.org Here are the specs on the original plans, but I slightly changed as noted next to the pictures. Thanks Mike for all your help.
The main body of the muffler is from 1 1/2" O.D aluminum. The center tube is 5/8" aluminum with one end bored out to tightly fit your tuned pipe stinger. The outer 1 1/2" O.D. muffler section I turned the inside to get a thickness of 1/16" since I couldn't find a thinner walled tube. If you can't find a thickness to your liking, you can use whatever you want, since this isn't rocket science. I turned mine down to 1/16" to help in keeping it light weight. The two end plates are 1/8" thick to give me enough room to use set screws to hold the plates in. I bored out the end plates slightly smaller than 5/8" so that I could get a pressed fit on the 5/8" tube. The inner tube has two thin grooves for two snap rings to hold the tube from moving in and out. I used a 10-32 standard treaded bolt with the head cut off to be used as a safety strap anchor in case the muffler would loosen and fall off. A small hose clamp hold the muffler onto the stinger of the tuned pipe. If you have any questions on building your own muffler feel free to contact me at martysrcboats.com
This shows the original 1 1/2" aluminum tube next to the cut and turned muffler tube. Click on the picture to the left for a bigger view.
This just shows the inside of the tube turned down to the thickness I want, which is 1/16" for weight considerations. Click on the picture to the left for a bigger view.
Here is the 1/8" end pieces that I test fitted into the muffler tube. These are turned down just enough to be pressed into the end pieces. Click on the picture to the left for a bigger view.
Showing the end pieces pressed on and secured by 3 set screws for each end plate. The set screws are long enough to be even with the muffler tube outside but penetrates the end pieces for a secure, tight fit. Shouldn't come loose unless I want them too. Click on the picture to the left for a bigger view.
This shows the inner tube with 16 holes drilled out for sound diffusion into the outer muffler tube. Should get the db's down to below 92db. Click on the picture to the left for a bigger view.
The inner tube is ready to be preesed into the end plates . Click on the picture to the left for a bigger view.
Here the inner tube is pressed into the end plates even with the spring clip grooves. Click on the picture to the left for a bigger view.
The tuned pipe side of the muffler showing the spring clip intstalled into the groove. Click on the picture to the left for a bigger view.
This is the exhaust side of the muffler showing the spring clip installation. Click on the picture to the left for a bigger view.
Closeup of the 10-32 bolt treaded into the inside end plate. You can see the safety strap installed. It is made of small size linkage wire with soldered circle end clips bolted to the tuned pipe bracket. Click on the picture to the left for a bigger view.
Finally the finished product. Doesn't look to bad either. Click on the picture to the left for a bigger view.
I'm having fun learning how to use my mill and lathe machines. Let's just say I have a lot to learn, but if you have any specific questions you think I might be able to answer then please email me here email@example.com
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