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How to Make a Straight Through Muffler

The straight through muffler incorporates a perforated tube design that allows the exhaust gases to expand quietly. For straight through exhaust the rule is the bigger the can the quieter the muffler, and they are considered to have the best flow design of most modern muffler types. The purpose of a muffler in states without yearly emissions certifications on vehicles is noise reduction. Installing a straight through muffler can reduce noise and can be tackled by most knowledgeable car enthusiasts. The right tools will make the difference with this job.

Instructions

1

Purchase the muffler and pre-silencer in the correct size for your car. Purchase the mandrel bends, or steel pipe for the tubes, from the same or another supplier. Be sure to get new exhaust hangers for the system.

2

Lift the car on a car hoist. Using jack stands is an option but will make working and welding beneath the car nearly impossible. If you are taking on this project it is advisable you either have access to or own the equipment to do the job correctly. Once the car is lifted examine the existing exhaust system for the location of the exhaust hanger mounts. Lay out the new system, noting the bends you need to use to accommodate the various mechanics the exhaust system needs to skirt.

3

Remove the existing system. Spray any clamps and hangers with silicone lubricant to loosen rust or dirt before loosening the clamps. Disengage the pipes from the catalytic converter, but do not disturb or remove it. This portion of the system needs to remain intact, and hollowing it or removing it could in fact hamper the performance of your vehicle. Replace any hangers or clamps that are damaged at this time.

4

Cut the mandrel bend sections for your system. Test fit the sections by placing them in the location beneath the car they will be mounted. Trim and adjust as needed.

5

Tack weld the pieces together. Check again for fit and be sure everything is aligned properly before welding the pieces together permanently and attaching the hangers. If the system is stainless steel you can leave it alone, but if it is aluminum or regular steel, paint with heat resistant paint created for exhaust systems to keep the surface from early corrosion.

6

Seam weld the pipe sections and muffler together and mount on the vehicle, welding in place. Secure all hangers and clamps. Start the vehicle and test the system for back pressure and flow.

Posted by Unknown at 2:15 PM

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