New Mufflers for Fun

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VOETOM

VOETOM

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Got bored again and needed to make some mufflers for a pal to tone down his non mopar currently running chambered mufflers.

Check these out.

They sound very smooth, very tame, and will flow a lot of air. I used the max size case I could to fit in his under chassis area, 5" by 11" by 17" long, 3" in and out. Took a bit to bend the shell using a press break but they came out very nice. These are sort of a hybrid version of a Goerlich Xlerator, a MagnaFlow and sort of similar to a Dynomax UltraFlo. They are light (16 and 18 gauge) but not st. st. as we did not need to worry about them lasting 100 years. I powder coated them with 1000 degree F DuPont Alesta "Pipe black".

The last image shows how we plan to attach such a huge muffler under a small car; three bolt flanges. This will enable the tailpipes to be bolted, not slid in and the same with the inlet. By doing this, we get a 17" muffler on a car where a 14" barely fits now.
 

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Next time, heat up the bare parts in your oven for a longer duration and at a higher temperature than you would to powder coat them. All of those little bumps and 'miniature volcanoes' are caused by air and impurities trapped in the metal and welds when they're formed.
 
The Chick has spoken.

Yall didn't take any pics of them being made? That's the part I wanna see. Otherwise, yall couldda bought them things at wal mart.
 
Hi Cuda Chick!
The real reason for the bumps ? I'll share the secret. I had the ends masked and while holding the mufflers on their hooks, and then untaping the masks, the powder was displaced and landed on the end caps. And as you know, one can't remove only part of the powder, you have to remove it all so I left it as is.

This powder has a rougher finish and in fact, we did preheat it after cleaning and the others I did were teated the same way. The finish is sort of a wrinkle type anyway on the test panels and the other mufflers and pipes I have built. Like I said, the real reason for the rough ends is the removal of the pipe mask that then dropped the excess powder on the end cap.

Greta catch Leanna, I am so glad you are paying such close attention. :):)
Thank you for the comments.

WalMart or others do not sell 17" by 5" by 11" sized cases. That is what is unique. To get sound control you need volume so maximizing the volume will get the bests muffler for actually muffling the sound level and trimming the crackle and roar out of very high flowing units. Thanks for commenting and I will show you what is inside if you want to see. By the way, I love your avatar. :)

Tom
 
Since your raw powder is held to the part basically through static electricity until you cure it, you can use gravity to your advantage on the next pair. Just hold a masked end and lightly tap on the other masked end so the raw powder falls off the edges onto the floor; then flip the muffler over and do the same with the other end.

I'll bet the hanging hooks were the biggest challenge to the job, especially if you ran them into the pipes. :-D I could just see that puppy wanting to roll over on its side in the oven LOL

I do like the color! Wrinkles take a bit of practice, and heating them up slowly will build your wrinkle height better than more powder will.

Way to go Voetom!!
 
Yeah I'd like to see it.
 
Right you are LeAnna, a hook all the way through the muffler which leaves one end susceptible to vertical powder collection/displacement.

Since I built them for fun for a pal and did so for only the price of the internal parts (roughly $30 per muffler) the powder job is basically a freebee. Plus I used plain old steel which will rust quickly when left unexposed so I had to coat them so they stay looking cool..

Stroker, I'll get some shots in a few.
Tom
 
StrokerScamp,
Here are the majority of the internal components.

* I used approximately 16" of the 3", spiral wound, 409 st. st perforated tubing. The pattern selected is "transparent" to sound, has good "porosity", and is commonly used by some of the best, highest flowing, and smoothest sounding performance mufflers.

*The stainless steel sock is used over the perforated tubing to keep the acoustic fiber from blowing out over time. Think of it as a filter; it lets sound through but not fiber material out. I slid a 5" long section on so you can see it.

*The aluminized tubes started as 3" , 45 degree Walker Exhaust components that I cut at the point needed to be able to get the 16" of perforated tubing inside a 17" case.

*Not shown is the ceramic fiber mat which is .50" thick and it used to absorb the higher frequency sound and give the muffler a smooth, non-farting, and non-crackling tone. Its minimum thickness is 1" so it has a good ability to absorb a lot of sound energy and cut down on the annoying noise passed through some non-packed mufflers.

Together, all the parts add up to create some of the more efficient mufflers I listed previously. The perforated tube and the stainless steel "sock" cost more than the chinese import mufflers do and that is why they are not found on some of the less expensive brands.

Hope this shows you what you were interested in seeing.
Tom Hand
 

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That's cool ****.


Got any recommendations for me? I have a 87 mustang I'm looking to put mufflers and tail pipes on. Motor is stock and will not be modified. All four cats will stay also. No one sells the stock ones anymore. Stock ones were actually different lengths to stop any drone at 2000 rpm. I don't mind a littl more sound but I don't want obnoxious loud and want to make sure I don't have a drone. It's a convertible family cruiser.
 
ABODYJOE, I asked the smartest muffler guy I know and here is what he recommended.

"Dynomax Super Turbo system 17491, for the 1986 Mustang GT 5.0L, is still
available. 17491 is a 2.25" OD system; same as the OE. Tail pipes are all
aluminized (no 304 SS rear section) and exit straight back with an angle
trim."

I hope that this helps and I most definitely agree with his suggestions, especially if you plan to run the cats.
Tom
 
THANKS.. YES IT HELPS A LOT.. sorry about the caps.. i searched some of the mustang sites and they all want loud. one site mentioned a drone at 2000rpm with the super turbos but i don't know if they had all 4 cats still.. i really like the super turbos on my dart so i'll give them a try.. i'll buy tail pipes elsewhere and sell the aluminized ones because i need the ss tails..lol..


found it at jegs... http://www.jegs.com/i/Dynomax/289/17491/10002/-1


thanks for your help.
 
That's very impressive. Nice work! I wasn't doubting you....just the opposite. I wanted to see it. Very nice indeed.
 
Stroker, never thought anything negative.... and I still love your Avatar. :):)
Tom
 
A Body; my pal said you may have a bit of slight drone, even with four cats. His words were "The Super Turbo mufflers in 17491 do have a little drone, but we don't get
many complaints about the sound."

So, take that as pretty much from the horse's mouth. If you need no resonation/drone, might need to go with more stockers.
Sorry!
tom
 
VOETOM said:
A Body; my pal said you may have a bit of slight drone, even with four cats. His words were "The Super Turbo mufflers in 17491 do have a little drone, but we don't get
many complaints about the sound."

So, take that as pretty much from the horse's mouth. If you need no resonation/drone, might need to go with more stockers.
Sorry!
tom
Click to expand...



i found the test.. here is what i was talking about..

http://www.allfordmustangs.com/Detailed/70.shtml



.
 
abodyjoe said:
That's cool ****.


Got any recommendations for me? I have a 87 mustang I'm looking to put mufflers and tail pipes on. Motor is stock and will not be modified. All four cats will stay also. No one sells the stock ones anymore. Stock ones were actually different lengths to stop any drone at 2000 rpm. I don't mind a littl more sound but I don't want obnoxious loud and want to make sure I don't have a drone. It's a convertible family cruiser.
Click to expand...

Dont mean to hi jack the thread but if your going to retain all four cats and stock dimpled headers than I think a obnoxious sound is going to happen. check out Pypes Race pro's. They are very surprisingly qiuet with zero drone. I have a set on my 5.0L convertible and they came out to be a too quiet for my liking, but I won't be switching them again anytime soon.
 
71swing said:
Dont mean to hi jack the thread but if your going to retain all four cats and stock dimpled headers than I think a obnoxious sound is going to happen. check out Pypes Race pro's. They are very surprisingly qiuet with zero drone. I have a set on my 5.0L convertible and they came out to be a too quiet for my liking, but I won't be switching them again anytime soon.
Click to expand...

I will still Have the obnoxious drone if I keep the stock header and all four cats??

You running all the stock stuff before the mufflers? Have any video of your car running?
 
Sorry no video. And no stock stuff here. I run a 70mm turbo before. LOL

The turbo does quiet the car a bit. But mustangs are my first love and I know that it’s louder than a stocker. I had flowmasters on the car before hand because I didn’t mind the drone (I don't think anything sounds better than a stang with flows.) But chamber mufflers are not ideal for turbo cars. So I searched around for a straight through muffler. Ended with the pypes. To my surprise they are VERY tame and quiet. Like I said above, too quiet for my liking. I will be switching them out for something louder later. I just didn’t want to throw away the money I spent on them. So I will live with them for the time being. But I would compare the sound very close to a stocker sound level. I don't have any drone at all, but that could be the turbo pre-exhaust that helps with that. I believe it’s the chamber in the mufflers that causes the drone.

I would think them on a car with stock headers and four cats would be even quieter. I now get into allot of trouble because everybody and their mom tries to mess with me because the car is stock sounding and they assume it stock until I pass them and let the blowoff valve release as I pass their window.

If you really want to get rid of the drone you could use dynomax VT muffler which claims to get solve the drone. I also know from past that dynomax are on the quiet side also, because I had removed them to put the flows on years ago.


http://www.dynomax.com/press_releases/dynomax®-introduces-revolutionary-drone-free-muffler.html
 
yea i have 3" dynomax super turbos on my dart and they are nice and quiet. but they are huge cases. have two other friends running the dynomax mufflers too. they are both quite a bit louder them mine. they are smaller case 2 1/2 i believe. the set on the 440 challenger with stock manifolds drone like mad.. hell the drone drives me nuts when i'm following him its so bad..lol.. the other 360 with full length headers i don't think does it but i'm not 100% sure..


i took the mustang to the shore the other night and at a little over 80mph i could hear where it would have a drone.. guess it had a slight drone but it wasn't one that would bother me.. my car has one stock ford muffler and one replacement muffler.

i had a 90 mustang rag top years ago that i put flowmasters on.. all stock other then that. it was great witht he 2.73 gear in it.. no drone and they were really quiet.. then i put a 3.73 gear int he car and man did the drone get annoying... it was horrible on the highway..

my biggest fear is spending the money on the mufflers and not being happy with them.. really don't want to spend money on mufflers 4 times just to get it right...lol. wish someone repopped the stock ones because i would just stick them on..

i'm not planning any major work to the car.. don't really want to do headers or anything.. may put gear in it but thats probably it.. its more a family cruiser...



I now get into allot of trouble because everybody and their mom tries to mess with me because the car is stock sounding and they assume it stock until I pass them and let the blowoff valve release as I pass their window.
Click to expand...

lol.. that has to surprise a few people..
 
Wanted to let you all know we got to hear the mufflers with 3" tailpipes on a twin carbed, tunnel-rammed 420 plus cu. in Chevrolet Nova and it sounds awesome sweet. My buddy said he felt like a grandma driving the car and is thinking of putting in a radio now.

Truly, it went from being a car that was able to be heard from 500 feet to being almsot stealthy, relatively speaking. It idles very quietly and never resonates or roars. Riding in it is quite a change compared to what it was with his chambered mufflers running in front of the rear axle with no tailpipes.

He has already got in some "street" races and had no issues with any of the local law enforcement folks hearing him coming.

I continue to be stunned and pleasantly excited when straight through mufflers that flow so much air turn out to be so quiet. The folks who make mufflers like these with this perforated tube pattern hit upon something....

Tom Hand
 
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