HOW TO: Build a detailed alluminium Tuner muffler

Bas Carwash
04-24-2005, 05:50 AM
Well guys, here we go. Iíve made a promise to do a how to on this a couple of months
back. Now it's finally here :D Enjoy

Hereís what I use:
5,6 and 7 mm aluminium rod with wand of 0,5 mm (available in every LHS)
Dremel with grinder
Xacto blade or knife
Flat file
600 and 1200 grit sandpaper
Metal polisher
30 minutes (after making 5 of these you do it in about 15 :D)

First of, some research. Most of the tuner style exhaust have a tip of about 100 to
120 mm diameter. So I, as a technical en mathematical genius :eek7:, am able to do
100 / 24 and 120 / 24. So the tip should be about 4 Ė 5 mm. As we use 6 and 7 mm
aluminium rod we get a outside diameter of the muffler of about 170 mm in real life.
Pretty realistic isnít it?

The pics below show the steps. Iím making a muffler with recess at the top and a
standard length for the tip. You can easlily change this if you prefer.

1. Take the Dremel with the grinder and take 25 mm of the 5 mm rod, 20 mm from the
6 mm rod and 22 from the 7 mm rod.

2. The small tubes look terrible after dremel using and I usually got some angled ends.
Use the file and Xactoblade to restore that. Donít worry about cutting to much,
wonít be a problem.

3. Take the 5 mm tube. As we want the tip to be very thin we start using the file in a
small angle and make the outside diameter of the tip smaller. I do this over a length of 4 Ė 5 mm.

4. The outside tube (7 mm) will give us a little bit of recess. It looks great and is easy
to create. Just take your blade and cut away the inside diameter in an angle making at
least 180 degrees rotations with every cut. The 180 degrees rotation is for a smooth result.
Make sure the length you cut away this way is the same as you want your recess to be.

5. Polishing!!! Yeah!!! Use the 600 grit sandpaper to smoothen the parts where you used
your blade and file on. Sand the first 5mm of the inside tube, the top of the middle tube
and the inner of the outside tube. Make sure it becomes extremely flat.
Tip!!! Wrap the sandpaper around the tube, easy sanding and only scratches along
outside of the tube which will give you a very shiny finish in the end. (See pic to
understand what I mean.)

6. Make the sanded areas smoother using the 1200 grit sandpaper. Making the
same moves as in step 5.

7. Use the Metal polisher to make the aluminium shine like a mirror! For the 7 mm
tube: just polish the sanded part. Weíll do the outside later.

8. Put the small tube in the middle tube using superglue to make it stuck. Make
sure your tip length is okay. It doesnít matter if there is a little bit of recess on the
other end. You can fix that later.

9. Put the large tube around the two others using your superglue again and make
sure the recess look the way you like it.

10. Almost done now. The back of the muffler isnít looking quiet nice yet, so
use your blade and file to make it look better.

11. Here we go, 15 minutes nearer to the end of the day and a beautifull
1 on 24 aluminium tuner muffler richer. Life is great :D

Enjoy guys, cheers.

Feint Motion
04-24-2005, 02:58 PM
Great Tutorial! This well help a bunch of people indeed.

04-24-2005, 03:21 PM
wow that looks pretty accurate nice tutorial

04-24-2005, 03:56 PM
Great Tutorial.. The Muffler Looks Perfect!! :D

04-24-2005, 07:40 PM
Great tut, Ill have to use that on th evo im getting soon...

04-25-2005, 12:05 PM
Looks great, but question, what size tubing would you use for the pipe from the cat to the muffler? 3mm? 4mm?

Bas Carwash
04-25-2005, 03:22 PM
Looks great, but question, what size tubing would you use for the pipe from the cat to the muffler? 3mm? 4mm?

Hmm... Good question there. Most exhaust pipes are like 2.5 inch. This would mean 2,7 --> 3mm tube in 1/24. I usually use the rod from the frames that come with the kits. They're almost 3mm in size.

Besides that, 4mm rod is hard to find for as far as I know. Evergreen has 3.2 as a max for rod. -->

They also have tubes with lots bigger sizes, but that's very hard to bend as it will nod. I think the rod from the frames is pretty accurate, unless someone is able to convince me otherwise of that...

08-02-2005, 09:58 PM
I am making a full exhaust for my RX-7 out of aluminum piping, I am going to study the kits that are available for the 1:1 RX-7 and base it off of that...I wish my car had an engine so I could make intercooler piping too :( Great job on the tutorial it will help me a lot.

08-02-2005, 11:28 PM
Whoa, old thread alert.

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