Topic: Making a baffle

[Johnny5]

Im seriously bored waiting for my seat to be delivered and thought I'd experiment with making a baffle for my 4-1 exhaust. I've done some searching here and google, but cant find anywhere that explains how to build your own.

Does anyone have any links? Or could explain how to build one?

Im sure it'll suck, but all my lawn/house work is done for the weekend and I just need a project.

[KB02]

Well, I've only got speculation and theories, so I don't know how much help I could be, BUT, I do have this website if you need parts:

http://www.coneeng.com/mufflers.html

[Alan F.]

Here's a page from Mike's XS, it shows a different type of baffle construction that the previous link. 

http://www.650motorcycles.com/megaphones.html

As long as it's centered in the pipe, doesn't rattle, and has holes that the exhaust pressure can escape through, you're in business.  Wrap your new baffle with fiberglass insulation (I understand regular house insulation will be OK) or lots of guys seem to be packing their baffles with stainless steel wool or stainless steel pot scrubbers, instead of fiberglass.  Packing a muffler will help quiet the sound.

The other method I've seen here is to cut the end off of an oil filter of the correct diameter, and attach it to the end of your muffler (either inside or outside will do) with sheetmetal screws. It's sort of a diffuser end cap.  I always thought this method would be cool with a pipe inside the muffler threaded into the center of the cap from the inside, you could drill it full of holes like a commercial baffle and cap the end with a pipe cap, then pack steel wool or whatever around it, then bolt it on.

Lots of luck, post back with pics and vids with sound too if you get something done that you're proud of...
-A

[clarkjh]

I took a steal roller, cut one end off, then filled it full of holes.  Welded it into the old mega phone and then put a cap on the end, drilled 5 holes in the cap to adjust the back pressure.  Wisper quite unless you cranked it, then it would boom out.

That's been over 15 years ago now though.

James

[Philly550K1]

does your megaphone already have a hole in it on the inboard/left side, for a baffle-mounting bolt? if not, will you have to "commit" to one with your baffle when it arrives, and will the baffle determine the placement of that hole?

keeping that one consideration in mind, you can easily bolt in different things until you hit on something. as far as packing, i had good results with a roll/sheet of fiberglass cloth, or "marine" fiberglass, from home depot. found it tidier than the cotton-candy variety. i made a "straight-thru" core out of wire mesh and loosely wrapped some 'glass around it. i was going for "loud-ish but tolerable" -- the fiberglass takes the nasty edge off the tone....  ymmv....

i like that oil filter idea. may have to play with some...

-jon

[Johnny5]

Thanks for the info.

Im trying to envision how the exhaust flows through the baffle. Does it actually pass through the packing? Or does the packing just sorta surround the exhaust flow?

[Don R]

Back when they were steel a 1 serving V8 juice can made an awesome baffle. Punched holes in both ends with a church key. Secure in the hooker Header with a screw. Also good for you to empty the can.

[736cc]

 Using an empty beer can as a baffle is old-school-cool...it works, too.

[Johnny5]

Is the front (part more inside the exhaust) of the baffle can more open than the rear?

[Alan F.]

Back when they were steel a 1 serving V8 juice can made an awesome baffle. Punched holes in both ends with a church key. Secure in the hooker Header with a screw. Also good for you to empty the can.

What size were those cans..12 oz?  maybe there's a current substitute?

[tomkimberly]

The old school cans were made from steel, they only use aluminum now. 


Tom

[mcuozzo]

Johnny,

I think it flows straight through. Look at this link.  But you already know, i don't know anything...

http://www.coneeng.com/mufflers.html

You can get a 10 inch perf. core baffle with enough steel wool for about $30.  But knowing you I have a feeling you want to make it yourself! 

Hope that helps somewhat.

Matt

[KB02]

Thanks for the info.

Im trying to envision how the exhaust flows through the baffle. Does it actually pass through the packing? Or does the packing just sorta surround the exhaust flow?

Packing surrounds the exhaust flow.
In theory, shout at the top of your lungs. Then shout at the top of your lungs using a wool blanket as a megaphone (hard to do, I know, but it creates a good example).

[Johnny5]

Ahhh, finally I get it. I'll post some pics and sound clips of my experiments when Im finished.

Thanks again!

[chrislib]

I made a baffle out of a 1 3/4 to 2 1/4 exhaust adapter, the type you`d likely find on the exh shelf at any Pep boys/Napa etc. The ID of my exhaust is 2 1/2 so I flared the very outer edge of the big end of the adapter so it was a snug fit inside the pipe. Then drilled a series of 1/4 inch hole along the smaller portion of the adapter and  wrapped that area with fiberglass insulation, I THEN wrapped the insulation with a few turns of stainless safety wire to help hold it in place. The whole shebang got slid into the exhaust tip. Heres a pic that should make it clear as mud.



The end of the tip has some type of "venturi intrecooler" type thing, all I know is it keeps the works from shooting out the end and it looks pretty neat.

[mystic_1]

Here's a good description:

http://www.cdxetextbook.com/fuelSys/intakeExhaust/exComp/muffler.html

mystic_1