Making a car muffler with your own hands

How to make a muffler with your own hands? DIY muffler repair without welding

Recently, more and more car enthusiasts are making and repairing mufflers with their own hands. But why are they trying to do it themselves if the car markets are overflowing with a wide range of spare parts? It all comes down to cost. Cost is the main barrier for car owners. Therefore, today we will look at how to make a VAZ muffler with your own hands.

Why does a car make so much noise when the car engine is running? The sound comes from two reasons, namely due to the expansion of exhaust gases and vibration of system elements. To combat this problem, car enthusiasts increase the weight of exhaust parts.

The thicker the metal, the less noise and unnecessary vibrations there will be. For this reason, automakers make the exhaust manifold more massive, since it is it that takes the first blow - hot gases from the combustion chamber of the cylinders.

By the way, for comparison, you can weigh the manifold of domestic and foreign cars. For the latter it will be much heavier. Therefore, our cars are an order of magnitude louder than imported ones. But this problem can be fixed. Of course, we will not change the collector.

We will transfer all actions to the following elements - the resonator and muffler. Gases under high pressure enter the first element. As a rule, its pipe diameter is larger than that of the muffler. After this, the gases lose some of their energy and are released under lower pressure.

Already in the muffler they practically dissipate, thanks to which we do not hear the characteristic rumble, as on a car without an exhaust pipe.

Due to the large number of fakes, it is very difficult to find a truly high-quality spare part today. And if such a part is found, the price for it will be simply exorbitant. Moreover, most of the complaints concern the elements of the exhaust systems.

The muffler rusts and burns out very quickly. Its service life does not exceed 1-2 years. It doesn’t matter how intensively you use your car. It burns out not from mileage, but from time. Even if the car is driven once a week, this will not add life to the muffler.

It will still have to be changed in a year or two.

After this time, car enthusiasts have a question about the need to replace or repair this part. If you repair the muffler yourself or make it from scratch, you can be sure that it will last much longer. After all, we will not skimp on important materials.

Also, by making a muffler with your own hands, you can add your own configuration to the exhaust system. For example, make a forward flow to increase engine power. However, driving long distances with such a “can” will be uncomfortable. Therefore, you can remake the system in a different way by adding an additional resonator to it.

This way the machine will run much quieter.

Before you make a muffler with your own hands, you need to decide on the budget and the option for reworking the exhaust system. There are several tuning methods:

Modification of a new factory muffler.
Making your own. By the way, you can make a muffler with your own hands using both stainless steel and ordinary steel.

Experts do not recommend using old mufflers or other parts of the exhaust system that have already been used. In this case, even if they look good (after all, they can be repainted before selling), the inside will be covered with corrosion or even burnt out.

Remember that with each engine start, the metal in the system heats up and changes its properties. It’s easy to guess what condition a muffler will be in if it’s been used for about 2-3 years on a car. Therefore, do not fall for the tricks of “lightly used” sellers and do not buy a used muffler.

Best of all, make it yourself.

https://www.youtube.com/watch?v=UbrTR6salXw

A less expensive solution from a financial point of view would be tuning the standard muffler. Making a part with your own hands from stainless steel is a very reliable, but expensive option. However, such an element will be more durable and will not burn out at the most inopportune moment.

When choosing this tuning method, it is best to completely redo the exhaust system. To do this, purchase a pipe of the required size (most often its diameter is from 30 to 52 millimeters). Of course, the thin-walled tube that comes to the car from the factory will be very difficult to find. Therefore, we use thin-walled tap water as an analogue.

The housing for the muffler is made from a car fire extinguisher. Moreover, the outlet and inlet holes should be shifted relative to each other. The ends of thin-walled pipes should be inserted 60 percent inside the container.

Numerous holes should also be made in them. As for partitions that are installed in factory versions, it is not necessary to weld them.

Using the same principle, you can make a muffler for a carbine yourself.

Due to the fact that the water pipe weighs an order of magnitude more than the one that comes with the part from the factory, you will have to strengthen the fastenings. In addition, you should insert the flexible corrugation into place that goes after the exhaust manifold.

Thanks to such changes, the noise level will be significantly reduced, and the service life of the part will be more than 2 years. By the way, the heavier the pipe, the less vibration it will emit.

In order to reduce the noise of a homemade muffler, it is recommended to fill its body with some material such as glass wool. It is also recommended to make a condensate drain hole at the bottom of the muffler. Thus, it will not rust prematurely and make extraneous noise.

If this is a muffler made with your own hands from stainless steel, it is important to think through its design. Make it partially collapsible.

This way you will periodically clean the pipe cavities from dirt and change the filler if necessary. Thanks to the collapsible design, the service life of the part will increase several times.

Do-it-yourself installation and replacement of the muffler is done in standard places. The main thing is to strengthen them, since the weight of the structure increases slightly.

Is it worth painting the muffler? There is no clear answer to this question. Most car enthusiasts say that the paint for it should be fire-resistant. Otherwise, it will simply burn. The ideal solution would be to make a muffler made of stainless steel. You can see an example in the photo below.

Using stainless steel will close the issue of painting once and for all. Well, you can paint the muffler on the carbine with your own hands with matte black paint. The main thing is that it is resistant to high temperatures.

How to repair a muffler with your own hands without welding?

Now there is a new method for restoring the performance of exhaust system parts using a universal composite polymer (various sealants).

Thanks to their special composition, they harden quickly and are not subject to external negative influences, including high temperature changes, which is very important for the exhaust system.

In car markets you can find two types of sealants, thanks to which you can repair the muffler yourself without welding:

In combination with high-quality reinforcing components, these types of sealants will create a reliable “patch” on the burnt-out section of the muffler. Car enthusiasts note the effectiveness of plastic elements. It is these sealants that are characterized by high adhesion to metal, even if there is rust on it.

Do-it-yourself cold welding of a muffler is done as follows. First, the surface goes through a preparation procedure. The area should be cleaned with sandpaper.

After this, the surface is degreased using white spirit, gasoline or another solvent. Next, you should prepare the adhesive composition. Cut off the required amount of sealant and knead it.

In the case of using liquid analogues, mix them thoroughly. Next, apply glue to the damaged area of the muffler and level the mixture.

Please note that the composition hardens within a few minutes, so all work with the sealant must be done very quickly.

Finally, you need to wait until the mixture dries completely. Depending on the brand of the manufacturer, this takes from 1 hour to a day.

To do this, you can install an additional muffler resonator. You can make it from scratch, like the muffler itself, or you can make it again from a fire extinguisher. However, the material of this part is not particularly designed for high temperatures. But, as practice shows, such resonators are quite effective in operation.

The most important thing when making an additional resonator is to place the tubes correctly. They must be offset relative to each other (everything is similar to making a muffler).

To swirl the exhaust gases, holes are made in the pipe. Thus, the gas pressure level decreases and they do not create much noise at the outlet.

As you can see, making a resonator for a muffler with your own hands is not so difficult.

The weight of the newly manufactured element should also be taken into account. If it is heavier than the standard one, you will have to strengthen the fastenings on the bottom, otherwise the part may come off right on the move. It is not necessary to fill the inside of the resonator, nor is it necessary to install partitions.

So, we found out how to make a muffler with our own hands.

Source: http://ya-prekrasna.ru/avto/kak-sdelat-glushitel-svoimi-rukami-remont-glushitelya-svoimi-rukami-bez-svarki

How to make a muffler with your own hands – Legal assistance

This scheme is already used on some brands of cars from the factory. mechanical adjustment of the damper is carried out on the go by the driver from the cab. It is possible to drive a short distance with the damper closed, but driving constantly is unacceptable for the engine.

the damper is installed in front of the muffler Manufacturing and installing the flute The flute (silencer) has more preferable characteristics. It dampens the exhaust pipe clearance much less than a damper. You can buy a flute, knowing the internal diameter of the outlet pipe, or make it yourself.

Various silencer designs are shown in the photo. factory models Flute mounting options Possible flute design options.

External - for outlet pipe diameters up to 50–60 mm. method of attaching a flute to a small diameter exhaust pipe
Internal - for large diameters.

Important

And this already reduces vibration during engine operation. The disadvantage of using the material is that you need to know how to work with it. Welding stainless steel is possible, for example, in an argon environment using special tungsten electrodes.

If you have experience working with stainless steel and a welding machine, then it will not be difficult for you to make several seams. By the way, you will have to do very few stitches. Do not forget about metal processing before starting work, the strength of the welded joint depends on this.

You can simply copy all elements from it. One pipe goes from the resonator to the muffler. Its shape is very intricate, so you will have to bend the new pipe literally millimeter by millimeter.

Most car enthusiasts say that the paint for it should be fire-resistant. Otherwise, it will simply burn. The ideal solution would be to make a muffler made of stainless steel.

You can see an example in the photo below. Using stainless steel will close the issue of painting once and for all. Well, you can paint the muffler on the carbine with your own hands with matte black paint.

Attention

The main thing is that it is resistant to high temperatures. How to repair a muffler with your own hands without welding? Now there is a new method for restoring the performance of exhaust system parts using a universal composite polymer (various sealants).

How to make a muffler with your own hands

The process of manufacturing a direct-flow muffler based on a standard one: Step one. Removing the muffler First of all, you need to remove the muffler from the car.

A VAZ car is considered as an example.
Next, take a grinder and cut out a piece in it, as can be seen in the photo. Subsequently, all the insides of the standard muffler are dismantled. Step two.

Making a muffler pipe Now we need to make a pipe, which will play a key role in the straight-through muffler.
In it you need to cut a series of slots in the form of a herringbone with a grinder. You can also drill holes with a drill.

Making a car muffler with your own hands

But this problem can be fixed. Of course, we will not change the collector. We will transfer all actions to the following elements - the resonator and muffler. Gases under high pressure enter the first element.

As a rule, its pipe diameter is larger than that of the muffler. After this, the gases lose some of their energy and are released under lower pressure.

Already in the muffler they practically dissipate, thanks to which we do not hear the characteristic rumble, as on a car without an exhaust pipe.

Why is a homemade element better than a factory one? Due to the large number of fakes, it is very difficult to find a truly high-quality spare part today. And if such a part is found, the price for it will be simply exorbitant.

Direct flow - how to make it yourself

The driver is charged for operating a vehicle with excess noise levels in accordance with the Technical Regulations of the Customs Union 018/2011 “On the safety of wheeled vehicles”, paragraph 9.9.

Table: dependence of the maximum permissible sound level on the vehicle category. Category M1, N1 and L are passenger cars with no more than 8 seats, trucks with a permissible maximum weight of no more than 3.5 tons, motorcycles/mopeds/ATVs.

Category M2 and N2 are cars with more than 8 seats (except for the driver), but whose maximum weight does not exceed 5 tons, and trucks with a permissible maximum weight from 3.5 to 12 tons, respectively.

Category M3 and N3 are full-fledged buses and trucks with a permissible maximum weight of more than 12 tons (trucks, most dump trucks).

Source: http://f1-help.ru/kak-sdelat-glushitel-svoimi-rukami/

Car exhaust system tuning

Over time, even the most sophisticated and sophisticated car, which you really liked at first, begins to gradually become boring. Therefore, many car enthusiasts want to make any changes to improve their iron comrade, or simply put their car up for sale.

But you shouldn’t resort to such radical solutions. There is a way out - you can modernize some parts of your car, for example, tuning the exhaust system. How to do it? In fact, there is nothing super complicated about this.

Just read our article to the end and you can see for yourself.

By changing a certain part of the car that you're tired of or just don't like, you can make it "shine" in a new way.

Quite often, car owners become bored with the sound of the exhaust, which they simply don’t have the strength to listen to every day.

To change the dull hiss of your swallow into a lion's roar, you need to perform the following procedure: do-it-yourself exhaust system tuning.

VAZ 2106, 2107 or Audi - the model does not matter, since this can be done for almost any car. True, in some cases the cost of tuning may be slightly higher.

Before we get started, let's touch on some theory.

Exhaust system design

If we talk about the most important elements of the exhaust system, then this is, of course, the manifold, on which the normal functioning of the system as a whole will depend. This unit serves to remove all accumulated exhaust from the combustion chamber of the car.

Initially, the gases enter special tubes, which are nothing more than an intermediate storage place for waste. Among tuning enthusiasts, the manifold is the ideal part for carrying out various types of improvements.

The fact is that a high-quality and clean manifold will provide the engine cylinders with a large amount of gasoline or diesel fuel (depending on the type of unit). This factor will increase the power of your car.

Car exhaust manifold

The converter is the next part belonging to the car exhaust system circuit. The main task of the neutralizer is purification: it removes all harmful components of the exhaust, reducing the level of toxicity to a minimum.

Examining the part in cross-section, you will be able to detect a ceramic shell consisting of many valves of small thickness. The inside of these valves is coated with platinum (of course, its layer is very thin) or other expensive metals whose properties are similar to each other. For example, it may not be platinum, but palladium.

In rare cases, a metal such as rhodium is used.

Catalytic converter

Then comes the resonator in turn. The main purpose of resonators is to expand the exhaust gases.

The procedure for sharp compression of exhaust gases makes it possible to significantly reduce the back pressure of the exhaust channel, due to which the shock wave is softened several times. The final stage we will discuss is the muffler.

The final sound produced by your car will depend on this detail, be it a bird chirping or a lion's roar. The modern automotive world is distinguished by three types of this system: absorber, limiter and reflector.

Exhaust system resonator

Having understood the device, you need to familiarize yourself with its main tasks (for those who are not yet in the know). The exhaust system serves to remove exhaust gases accumulated in the intake manifold of the vehicle.

In addition to the main tasks, this system performs secondary functions, such as purifying combustion products and reducing engine noise. When tuning the exhaust system, take into account its main functions so that various interventions do not affect the exhaust gas purification function.

If there are even the most minor changes in the environmental purity of exhaust gases, the vehicle owner may encounter problems during mandatory maintenance.

This is what a car exhaust system looks like

To be brief, the system structure is divided into 3 parts. The first of them, the intake manifold, collects exhaust gases and participates in their transportation to the outlet.

The neutralizer plays the role of a filter element, purifying gases, which reduces their toxicity level. A muffler, as the name suggests, muffles the sounds coming from the car.

The muffler is designed in such a way that the speed of the exhaust gases emanating from the catalytic converter is damped. This affects the noise level of the system.

Why do you need tuning?

There is no clear answer yet that would confirm the need for tuning. But quite often, when any part of the exhaust gas exhaust system fails or begins to function incorrectly, car owners begin to consider an option such as tuning.

Some decide to do this work with their own hands, while others immediately turn to specialists - it’s up to you to decide. For those people who have decided to tune the exhaust system on their car, it is worth familiarizing themselves with all the possible types of tuning for this part of the car.

In addition, some of them can be done independently, without outside help.

Audio tuning

This type of tuning allows you to influence the sound of the engine, changing it to a more sporty one. Many have heard cars rushing through the city streets, emitting a wild “roar” - to create such an effect, audio tuning is required.

Carrying out audio tuning of the exhaust involves replacing the catalyst with a special flame arrester.

After the catalyst is removed, it is necessary to install a direct-flow muffler (direct flow), which creates the movement of working gases in the heat exchanger in one direction.

This is what audio tuning looks like

Video tuning

The essence of this type of tuning is to change the exhaust gas exhaust system visually (use of special nozzles). It differs from other types in that it does not require intervention in the design of the exhaust system.

In addition, the costs of performing video tuning are insignificant, which makes it more affordable for car enthusiasts.

There is such a feature as “dragon tongue”, which can be done with video tuning, but such a toy requires a lot of time and money.

Video tuning of a car exhaust system

Performing technical tuning

Another type of car tuning is technical tuning. It is used to increase the engine's horsepower (power). By performing technical tuning, you can increase the power of your iron horse by about 10-15 percent.

In this case, it is very difficult to do all the work yourself, because technical tuning involves a complete replacement of all elements of the system, so many motorists turn to specialists for help.

Regarding the financial side, this type of tuning is considered the most expensive pleasure, and besides, your car will consume more fuel.

Performing technical tuning

Let's look at tuning in theory

So, you have finally decided to make some adjustments to the operation of the exhaust system. There are quite a lot of advantages to this. It’s worth starting, perhaps, with an audit that will be carried out during tuning.

In addition, this way you can show your imagination. But don’t forget that tuning the exhaust system at home is not always easy, it’s not like changing a tire, you need to think about it.

Of course, there are different types of tuning, which we have already mentioned, depending on which the amount and complexity of the work may vary.

If the car owner decides to stick with the usual replacement of the exhaust pipe trim, then performing this operation will not be difficult for him. But we will consider a more complex option, in which the exhaust sound changes and the car’s power is increased.

This issue must be approached wisely

You need to approach this issue wisely, having studied the issue from all possible sides. Make a detailed plan, writing down on a piece of paper all the planned replacements.

If we talk about the most optimal option, then this would be dismantling the manifold, converter and all other parts of the muffler of your car. Take all necessary measurements and record the data.

If you were unable to obtain measurement data, then you can use the Internet and, by entering the model of your car, find all the information on this issue. After this, you can start tuning.

How tuning is performed

Initially, you need to take care of the necessary tools and materials. And if you can easily find all the tools in your garage, then you will have to go to the auto store to get the materials (a new spider and part of the muffler). You can buy a spider, or you can weld it yourself (if you have the opportunity and skills).

Types of spiders

If you are unhappy with the sound of your car, there are two ways to fix it. The first is to go to a workshop, where they will do everything for you for a certain amount. The second (cheaper) is to find a car model on the Internet with the sound you like. Have you chosen? Great, now go to the disassembly site and buy the latest can of the exact model you found on the Internet.

Having prepared everything you need, you can begin installation. After removing the old collector, install the spider in its place. Then you need to tighten the fastening nuts thoroughly.

The next step on the path to getting a good sound from your car will be installing the purchased can on the muffler. Often you will be hampered by the fact that the two parts have different diameters.

But this is not a very serious problem, especially if you have a welding machine. It is necessary to pay due attention to the junction of the new muffler can with the engine so that it can fit perfectly into place.

If necessary, the jar will need to be slightly altered.

This is what the can looks like at the end of the muffler

We smoothly approach the final part of tuning, which is also considered the most enjoyable. Start your vehicle and listen carefully to the sound coming from the exhaust pipe.

At the same time, choose different engine speeds, changing them periodically. The result of your work will not go unnoticed.

Now, as a reward for the work done, you can drive through the streets of your city at different speeds, enjoying the new sound - this is how your car now sounds.

Using this simple method, you can improve your car, or rather, its exhaust system. The main advantage of this type of tuning is that the driver will be able to independently perform all the necessary work, while influencing the sound and making certain adjustments.

Price issue

Is it worth tuning the exhaust system for domestic car models? And how much will it be? You can hear from many experts that such tuning work can increase the power of your engine by about 8-10 horsepower. Moreover, this figure is not related to the place of engine production; you won’t be able to add many horses on foreign cars either. For more serious performance, you need to install a turbocharger, but we will talk about this later.

Exhaust system tuning – do you need it?

To determine the approximate cost of tuning, we collected average prices for the necessary parts. For example, a collector will cost you about $140, a corrugation - $20-25, a resonator - about $30, a muffler - $150-250 (depending on the manufacturer).

The cost to install these components at a service station is $100. In total you will spend 400-500 dollars. If you are the happy owner of a VAZ-2109 or 2107, then it will cost you about $70 for everything, but with foreign cars the situation is different.

Therefore, before tuning, think: do you need this lion's roar of the car?

Video - Replacing the exhaust system on a Mitsubishi Lancer. Tuning

Source: http://na-dorogu.ru/tjuning-vyhlopnoj-sistemy-avtomobilja/

Making a car muffler with your own hands – Automotoguru

On many cars, the structural components of the exhaust pipes are problem areas. They often fail, burning out or rusting. New car systems for muffling the sounds of a running engine sometimes do not last even a year after replacement, becoming unusable.

This situation pushes some car enthusiasts to the idea of creating a muffler with their own hands using a more reliable and durable material for manufacturing. Agree, you don’t want to spend money almost every year on buying exhaust pipes.

In addition, you can try to make a running car quieter.

The role of mufflers in cars

The exhaust pipe system, despite the apparent simplicity of its purpose, performs several important functions, namely:

a significant reduction in the intensity of sound phenomena occurring during fuel combustion;
reducing the temperature of gases that initially have very high thermal indices;
reduction of exhaust gas toxicity.

A homemade muffler can be made from scrap materials. How a car exhaust pipe works

Modern pipe systems that remove exhaust gases from the engine, simultaneously converting them, consist of several sequential functional elements:

Corrugated pipes extending directly from the exhaust manifold. These elements do not have the rigid structure necessary to ensure that engine vibration is minimally transmitted to the entire pipe structure.
A catalyst where the most environmentally and hygienically dangerous compounds formed as a result of the combustion of hydrocarbons are deactivated.
A resonator, which is a special expansion along the path of gases passing through the exhaust system. Here the primary inhibition of gases occurs, where the pulsating flow turns into a slower and smoother one. The standard resonator is designed to dampen exhaust pulsations of a certain frequency characteristic of this engine.
The muffler, where the exhaust finally loses speed and temperature due to dispersion. This formation has a rather complex design, designed to disperse the gas flow as much as possible and absorb sound vibrations.

The performance quality of each structural element of the exhaust pipe depends not only on their design, but also on their weight. The heavier (thicker the metal) the same muffler, the less it perceives all kinds of vibrations. That is, the exhaust sound becomes quieter.

The bifurcated exhaust for the muffler is ready. A method for making a muffler for a car yourself

To make a homemade device, you will need an outdated automotive powder fire extinguisher. This model of a homemade muffler is not only effective, but has also been tested many times, so it deserves attention. For work, in addition to a fire extinguisher, you will need the following materials and tools:

two-inch (inner diameter) steel pipe or two sections of it;
some elements of the old muffler;
electric welding machine;
welding electrodes (1.5—2.5 mm);
small grinder with cutting wheels for metal.

Further work is carried out in this order:

The head of the fire extinguisher is turned away and the remaining powder is poured out. The hole is expanded to such a size that the prepared pipe fits tightly enough.
On the other side of the cylinder you need to prepare the same hole, but shifted towards the wall of the fire extinguisher.
On the final sections of pipes (12-15 cm), those that will be located inside, round holes or through cuts should be made using a grinder.
The prepared sections are inserted into the cylinder. In this case, it is calculated that the perforated areas are approximately in the center and opposite each other. We weld the connections on both sides of the cylinder in a circle, being careful not to burn through the metal of the fire extinguisher.
We cut off the fastening devices from the used muffler and weld them onto a homemade product, calculating and marking with chalk the place of attachment to the car.
To check the reliability and tightness of the welds, you can plug one of the pipes with a reliable plug, turn it over and fill it with water. There should not be even minimal leaks.
After draining the water and blowing the product with a compressor (to completely remove any remaining liquid), you can install a self-made muffler on the car.

A plugged tube is welded into the fire extinguisher, it has 70 holes with a diameter of 5 mm

In this way, spending a minimum of resources and a little time, you can solve the problem of how to make a muffler with your own hands. A car equipped with such a reliable device will operate more quietly, and you will not have to spend money on purchasing a new exhaust system every year.

Source: https://avtomotoguru.ru/delaem-glushitel-avto-svoimi-rukami/

Instructions: How to make a forward flow with your own hands, pros and cons

Many modifications are made to a car to attract the attention of others. Most often these are cosmetic changes, but there is one functional upgrade that is popular among car tuning enthusiasts.

It allows the driver not only to express himself to others, but also to improve the power characteristics of the car. We are talking about installing a direct-flow muffler, which is commonly called a direct-flow muffler.

In this article, we will look at how to install direct flow on a car, as well as what pros and cons it brings.

We recommend reading: DIY muffler repair

How to make a forward flow with your own hands

A good direct-flow system produced by sports car manufacturers costs serious money, and the desire to make a direct-flow system yourself is quite understandable.

If you look at such accessories in detail, you will notice that they are a standard exhaust outlet with a modified design - smoothed bends and a small number of welds.

Due to this structure of the exhaust system, it becomes easier for the car to cope with the emission of exhaust gases into the atmosphere.

Making a forward flow with your own hands is not as difficult as installing it on a car, but you should understand that such interference in the design of the car has its own effect on different models. Most often, a homemade direct-flow system is installed on “weekend cars” that were purchased in order to conduct various experiments on them.

To make a direct flow yourself, you will need: a metal pipe with a wall thickness of at least 3 millimeters, a welding machine, a drill, a grinder (for cutting metal), stainless steel (metal sponges for washing dishes are most often used - about 50 pieces).

The process of self-production of direct flow is as follows:

It is necessary to remove the installed muffler from the car and open the resonator. To do this, take a grinder and make a hole along the entire length of the resonator, and then spread the metal sheets to the sides, as if opening a tin can;
After this, you will see all the insides of the resonator, which consists of two parts of a pipe and several stiffeners. All this has to be cut out of the resonator “to zero” so that its metal shell remains directly. The most convenient way to cut is with a grinder, but be prepared for the fact that it will take a lot of time. When removing pieces of pipes, leave 3-4 centimeters on each side to make it easier to weld modified exhaust options later;
Next, we take a pipe of the same diameter as the pipes remaining sticking out in the resonator on both sides. We cut it so that it is long enough to be installed in the resonator between the cut pieces and welded using a welding machine. It is important to remember the rule here: “Measure twice, cut once.” If you change it incorrectly and the cut pipe size turns out to be shorter in length than necessary, you will have to cut a new piece - it is prohibited to fold this part from several pieces of pipe;
When the pipe of the required length is cut, we must begin to modernize it. To do this, take a small diameter drill and make a lot of holes in this piece of pipe. At the same time, leave 3-4 centimeters of pipe on each side so that reliable welding can be ensured. If your drill cannot handle the pipe, you can use a grinder and make many cuts on the pipe every 1.5-2 centimeters.
After this, it is necessary to weld the holey piece of pipe onto the parts of the pipes that remain sticking out in the resonator;
When the piece of pipe is securely welded, it is necessary to fill the entire resonator with mesh stainless steel. To do this, take 50 purchased metal dishwashing sponges and start placing them in the resonator, filling all the free space.

Attention: some sponges may come with improvised “hooks” made of paper, plastic or fabric. Such elements must be removed from the metal before placing it in the resonator.

Next, close the resonator and weld the lid securely;
At this point, creating a direct flow with your own hands can be considered complete. All that remains is to install the car muffler in place.

It is important to note that this method is only one of many options for independently creating a direct-flow pipe from an existing muffler. Some car enthusiasts assemble direct flow from scratch, which is much more expensive and more labor-intensive. This modification is simple, and even a driver without experience can perform it.

Pros and cons of installing direct flow on a car

Installing a direct-flow system has both pros and cons. Each motorist decides for himself how appropriate it is to modify the car muffler in favor of direct flow.

Pros of direct flow:

If a pipe with a slightly larger diameter than originally installed is welded on, it is possible to increase the exhaust gas throughput. An increase in airflow leads to an increase in engine power, up to 15%;
Increasing the service life of the muffler. Most often, the muffler “from the factory” is not made from the best materials, but with such a modification, the motorist can use good pipes, even titanium options. If you want to increase the “lifetime of the pipes,” then after welding the resonator, you need to remove the end of the muffler with a grinder and solder a new pipe in its place, having thoroughly cleaned and primed it in advance.

Disadvantages of forward flow:

Increased noise. Many car enthusiasts consider this parameter a plus and install the direct flow with their own hands solely for the purpose of increasing the “rumble” of the car when driving;
Reducing the vehicle's ground clearance if pipes of larger diameter are welded onto the muffler;
Problems during maintenance. Increased noise and the absence of a catalyst will lead to problems during maintenance;

The method of installing a direct flow with your own hands, described in this article, can be called “collective farm”.

In professional racing cars, the direct-flow system is much more complex and is designed primarily to improve engine performance.

At the same time, such a forward flow is unlikely to bring much benefit, only changing the sound of the car, which, in most cases, is the goal of independent tuning.

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Source: https://okeydrive.ru/kak-sdelat-pryamotok-svoimi-rukami/

How to make a muffler with your own hands

27.02.2015

Since the birth of the internal combustion engine, driver sound comfort systems have been installed on this unit.

Many years after its invention, major sports car manufacturers began to optimize the internal layout of the exhaust muffler to find a compromise between engine efficiency, driver and passenger comfort and creating a spectacular sound of the car.

Today, the market offers many different custom exhaust systems that can be integrated into almost any car.

What an average older car driver has to face, how to avoid premature wear of important parts, and what to do if a breakdown occurs - in our article today. As a bonus, we’ll tell you how to assemble an exhaust from scrap materials that sounds very close to the famous Italian sports cars Ferrari.

The exhaust system is exposed to increased external influences every day. As the vehicle is used, the device in question is influenced by factors that gradually disable the muffler. Elements of the exhaust system are subject to mechanical and corrosive damage and become faulty over time.

But not every owner is in a hurry to go to a car service center to weld the muffler or to a related goods store. After all, anyone can make a muffler with their own hands. Modern materials allow you to build a muffler on your own, even without special equipment at hand.

Detailed instructions on how to do this are below.

Factors that destroy the muffler

A damaged muffler will not go unnoticed by its owner. After all, the consequences are quite unpleasant. With a broken muffler, we hear an unpleasant hum or even a roar when the car is running.

The audible vibrations produced by the exhaust pipe of a car if the muffler is not working correctly will not leave the owner indifferent. Many of us are not satisfied with the quality of the mufflers and the only alternative is to make the muffler ourselves.

Despite its originality, a device created by yourself can turn out to be of very high quality. If you follow all the details during installation, you will get an excellent - quiet muffler. Making it is not so difficult, but still, knowing the cause of the malfunction, you can try to restore the old mechanism.

In order to successfully restore an old jamming device, you need to get to the point of its failure.
Some of the most common reasons for failure:

Exposure to high temperatures

If the exhaust gas heating rate is high, corrosion protection is powerless. The inside of the gas exhaust pipes will be subject to extreme heating and suffer from the catalytic reaction of the metal and exhaust gases.

Often, the interior of structural elements deteriorates faster from the inside than from the outside. This is especially noticeable if the car is often started and used at low mileage - this has a much more detrimental effect on the entire system as a whole.

If you want to avoid problems, try to operate the car in a mixed cycle and avoid traffic jams, this will keep all systems in working order for the warranty period.

Impact of mechanical shocks

Stones found on the roads often accurately shoot directly into the banks of the jamming circuits. This must be especially taken into account when driving along sections of roads that are under repair.

Current methods of asphalt repair make it possible not to stop traffic by regulating the passage of vehicles along the lanes, but at the same time, traffic is carried out in areas with an unprepared surface covered with crushed stone and sand.

If an unprepared driver overcomes such a surface at a speed above 40 kilometers per hour, then the crushed stone that has been compacted, but not filled with tar, scatters under the wheels and ricochets across the entire bottom of the car. We do not recommend this approach to crossing repair zones for many reasons, including road safety.

Moisture

On the road, we may encounter puddles of chemical elements, which in turn affect the structure of the car's components.

Components that are sprayed by special road harvesters lead to severe corrosion on external components located at the bottom of the machine.

This happens every winter season, and the degree of degradation of hull materials directly depends on the time spent on the road. Not very good workmanship of the device, or a manufacturing defect.

These conditions often compromise the integrity of the exhaust system. The production technologies for these spare parts are very primitive, and for most cars their welding is robotic.

Unfortunately, quality control of output products does not guarantee the absence of defects in all products. Otherwise, the cost of the final exhaust muffling device would be disproportionately large. It is unlikely that anyone will agree to buy a muffler that costs a quarter of a car.

With increased use of the car, such defects degrade to the point of through holes, frequent cracks, etc. Considering that the sounds of a faulty muffler are too obvious to ignore, the question arises quite acutely.

The first thing car owners who have the appropriate equipment do is weld and restore the affected parts of the car's exhaust system.

DIY restoration

Do-it-yourself muffler repair allows you to save money and realize exactly the exhaust sound that the owner expects.
Before carrying out work on creating a muffler, it is necessary to estimate the budget and find out the materials used. There are several options and each of them has its own pros and cons. In general, they can be divided into 3 parts:

modernization by installing a new muffler from the manufacturer
creating your own muffler model using inexpensive steel
creating a high-quality device using high grade stainless steel

Do not use the main components of unsuitable exhaust systems. Also, do not use materials that have signs of corrosion or external damage. Due to constant exposure to high temperatures, metal changes its properties and becomes less resistant to mechanical and chemical influences of the external environment.

If you want to save money, then upgrading by installing factory elements is suitable for you. Making your own device using high-grade steel will be more expensive. But with a reasonable approach to business, this model is the most reliable and durable.

In practice, there are several effective ways to repair a muffler yourself. It is possible to do this:

Welding the affected areas of the filter
Restoring the area with sealant
By constructing a special harness (fiberglass or similar materials are used)

These methods will help you make a quiet filter with your own hands, even if it is slightly damaged. Based on the scale and area of damage, the most convenient and effective method is chosen. If the structure is damaged, directly on the cylindrical form, it is most convenient to carry out reconstruction using strapping.

This type of restoration is also convenient for multiple lesions in the sound filter area.
The material used has a special impregnation and is very resistant to high temperatures, so there is nothing to worry about. Welding will help restore the large size of the affected area.

Even with large-scale cracks, with the help of welding it is possible to restore the structure and again give the system its former tightness, for the full functioning of the device.

Restoration work

First, let's look at restoration using cold welding. Nowadays, almost every motorist has mastered this technique. The composition of this consistency quickly takes the required shape and hardens in it. At the same time, it is quite resistant to various influence factors.

Today, there are two main types of sealants - liquid and flexible. Liquid sealants will also help to make bandages on the muffler. The combination of the two materials will give an improved result and give you back a quiet muffler. Flexible polymers that have a structure resembling plasticine in appearance.

They attach well to metal, even with severe damage. Instructions for using sealant.

First of all, you need to completely clean and degrease (you can use a handy product - gasoline) the surface. Then, we eliminate the unevenness using sandpaper.

Now, you need to prepare the composition for restoration. Flexible - first knead with your hands and stretch out the required amount. Liquid - stir until it reaches a homogeneous consistency.

Apply the composition evenly to the damaged area. When using an already prepared composition, it is necessary to quickly apply it to the surface.

These sealants quickly take on a solid state.

After restoration, you must wait until the composition has completely hardened. If the car is used prematurely, the structure will be damaged. Depending on the material, drying time varies. Before carrying out work, carefully read the instructions for the composition.

Homemade mufflers

It is also possible to make a device that removes noise with your own hands. Some motorists decide to make an analogue with their own hands and assemble the muffler with their own hands. Stainless steel or other metal acts as the main component, a potential structure.

Fasteners for installation can be used from an old device. With a competent approach to the matter, it is not difficult to find the dimensions and parameters - in the instructions. If you want to accurately recreate the structure and dimensions of the old device, find the appropriate description.

Main conditions and creation technique: The exhaust pipe element must be located along the body and inserted inside, with a free space equal to half the total length. The outlet opening should be close to the side wall. The outlet pipe is immersed approximately 0.7 cm inside the main pipes during installation.

A worthy alternative to repairing with a sealant is to make a device from an old fire extinguisher. Necessary actions:

Making the powder fire extinguisher empty (freeing up internal space)
Removing the faucet
On the surface of the case, we make a hole equal to the tube of the future device.
We also make a hole at the bottom, but this time closer to the wall
We make holes in those sections of pipes that will be located inside.

This was the preparation stage. Now you need to try on the structure in the area of the standard muffler. If the hole is aligned with the pipes, securely fix the device by welding. We remove the components and complete the assembly.

We looked at several ways to restore a silencer. Melon options are the simplest and most effective, but far from the only ones.

There are quite a large number of schemes that allow you to restore the operation of the device in question.

When making a muffler, use stainless steel, this will significantly increase the service life of the new muffler. By creating a design that is easy to disassemble, you will add the ability to replace individual parts.

Recommendations

When purchasing a new muffler, you should not save money. Cheap mufflers are made from the simplest materials and low quality workmanship. An element made of high-quality steel can serve faithfully for a long time. It must be remembered that the exhaust system of a car is often exposed to external influences and is one of the most vulnerable.

Do not allow the muffler to be completely destroyed. It is easier to eliminate malfunctions in the early stages, which will not require further effort to repair the muffler with your own hands. It requires much less time and effort.

Remember that since 2004, administrative liability has been introduced for increased noise produced by a car.

If, as a result of damage, your car produces a sound that exceeds the standard (96 dBA) specified in GOST R 52231-2004, which was issued by the State Research Institute of Automobile Transport, then prepare to receive at least a warning when meeting with the inspector, and at worst circumstances and a fine of 500 rubles. The only way to avoid these costs is to convince the inspector that this violation can be corrected on the spot, and do so. In general, the owner is unlikely to like such an exercise, especially in the dark and in the autumn-winter season, when the ability to get to the exhaust system on the road is associated with receiving mud baths, which have absolutely no medicinal properties.

Although, of course, you can take the sporty route and organize the production of a direct-flow muffler to replace the damaged one.

This type of muffler will increase engine power and provide better transmission of torque to the wheels than in the standard version, but will definitely disturb passersby. After such work, do not forget to record a video of the exhaust and share it in our VKontakte group.

Carry out periodic diagnostics of all parts and systems of your own machine. Do not risk your own safety, as well as the safety of your passengers and pedestrians.

Source: http://carmend.ru/body/posledstviya-vibracij-ili-kak-sdelat-glushitel-svoimi-rukami.html