Standard car mufflers are mainly made of iron, which allows auto manufacturers significantly save on materials. However, such systems are notable for their short life, which is a susceptibility to corrosion and relatively low mechanical strength. Conventional, stock mufflers, with intensive use of the car, can burn out in 3 to 4 years, which entails additional financial costs for repair or replacement.
In this article, the author proposes a self-made muffler project made entirely of stainless steel, the advantages of which are obvious over iron: the strength and heat resistance of such a muffler will be much higher than that of a factory muffler, and it will never rust. The service life of such silencers is about ten years.
To create a silencer you will need:
- 1 mm thick stainless steel sheet;
- Stainless pipe 76 mm;
- Stainless pipe 47 mm;
- Chips of copper;
- Brass shavings;
- File;
- drill;
- Bulgarian;
- Welding machine, argon or semiautomatic device.
Step 1. Internal partitions.
Having decided on the size and shape of the exhaust pipe, you can begin to create internal partitions. Their shape matches the shape of the exhaust itself. Partitions are made of sheet steel, 1 mm thick. The external contour is marked and cut, it is the same for everyone. Inner holes in two of them will be 47 mm in diameter, and in the other two - 76 mm.
To make such large openings, it is necessary to mark circles in the center of the partitions, the diameter of which is slightly smaller than the required one (by 5 - 6 mm.). Then, marks are punched around the circumference of the circle (the distance between them depends on the diameter of the drill, which you will later use) and a small drill (3-4 mm.) Drills holes around the circumference. After that, the inner part is knocked out and bored with a rough file to the desired diameter.
Here's what you should get:
Step 2. Pipes.
Further, holes must be drilled on the pipes. The diameter of the holes is 4 - 5 mm. The distance between them is approximately equal to the diameter.The part of the pipe that at the end of assembly will be inside the muffler is drilled.
Here's what they look like:
A pipe with a smaller diameter will be installed at the inlet of the muffler, a pipe with a larger one will be installed at the outlet.
Step 3. Welding.
Now it's time to put the elements together. Having decided on a long muffler, we cut out the desired piece from a stainless sheet (1 mm.). Its length will be equal to the length of the muffler, and the width should be about 10 centimeters less than the circumference of the partitions, so that during collection there is access to the inside of the muffler.
Partitions are set at an equal distance from each other, grabbed by welding in the middle. Then the sheet bends around them and is welded.
It should be like this:
Then the pipes are welded. Each of them occupies one extreme chamber, the central chamber remains free.
Step 4. The inside.
Inside the silencer, three chambers turned out. The first chamber is filled with copper and brass chips. Chip is used for sound absorption and damping of the resonance of the housing.
In the central part, a partition is placed to disperse the exhaust gases.
The last camera remains empty.
We make a technological "window".
The silencer is ready:
