Need a tip for my tips

i asked this question a while back, but it was deep inside one of the other threads so it probably wasn't seen by many, and i need some suggestions because i'm stuck! i have bought 2 aluminum pipes of different diameter's with which to make exhausts (decided i'd rather have real metal then painted straws). the tube for the tip is a 3/16 diameter, while the one for the cannister is a 9/32. my problem is that the tip is alot smaller then the cannister (any bigger and it would've looked too ricey IMO), so i was wondering if anyone has any ideas of what i could use to make the "wall" in between the cannister and tip (RyanGiorgio, for example, used paper on his straw exhausts). i don't want to fill up the pipe with clay as that will weigh it down and it will lose it's hollow-ness. someone suggessted JB Weld, but as you can see from the pics below, the tip tube has enough room to move very freely around inside the cannister, so i can't really use glue or JB Weld or anything like that, if you know what i mean. take a look at the pics and you'll see what i mean. the tip tube is inside of the cannister tube in the pics.

http://files.automotiveforums.com/uploads/940956smalltubes.jpg
http://files.automotiveforums.com/uploads/257042smalltubes2.jpg

Just throwing out some ideas:

Make a set of grommets out of sterene sheet?

if you twirl your knife around the inside edge of a scrap piece of the tubing, you should be able to sharpen the edge a bit. then you can "stamp" out a ring of plastic that matches each diameter.

uhh... let's see ... double check your work when lining up the centers... You'll probably have to make a bunch to get a couple "true" donuts. then you could line up a few in a row inside the larger tube to make sure the smaller tube is held straight.

A little bit of an impression at the tip end, and you could simulate the corner welds, i think.

I have 2 suggestions;

First, use styrene tubing for the cannister instead. Depending on what you can find, you may be able to get hold of tubing that has a thicker but will allow your aluminium tube to slot inside solving your problem immediately. Alternatively two different diameter tubes with thinner walls will slot into one another.

However, it not real metal is it! I say thats not an issue, if you paint the plastic in whatever metalic paint you can acheive a more realistic muffler as many have contrasting finishes between the cannister and tip - take a look around.

Second, in a similar fasion use differen diameter tubes which will fit into one another telescopically. In your case you need the size to fit between the two. Then, leave the tip sticking out and fill in the wall of the cannister with JB Weld (sparingly) and file to shape. Once again you often find a different finsh to the wall anyway.

Pic shows a still incomplete S2000 replacement exhaust and some of my styrene and alu tuding - some too big for mufflers though.
http://files.automotiveforums.com/uploads/7828181.jpg

hmmm...those are both good ideas Chris. but i've already bought the aluminum cannister tube and it looks like it might be a while until i make another trip back to the hobby shop to purchase more styrene tubing. i think, so far, i'm going to have to give Jay's idea a try...another thought i had was maybe finding some sheet-metal and cutting a circle somehow that would fit the opening of the cannister, but with that there's the issue of trying to make a hole for the tip to go into...i'll give Jay's idea a try, but more ideas are welcome from anyone who has them!!:D what about putty...??

Ok, in that case if you have some styrene sheet, rather than try to punch holes cut a strip of 2-3mm wide perhaps and glue it to the outside of the smaller diameter tube so that you create a ring of plastic around it. You can then slide that inside, sand it to fit, add more plastic, whatever!

now that's a good idea!! the only styrene sheet i have right now is the "metal siding" (i'm going to take a stab at making an intercooler this weekend), would that work?

No reason why not! Just cut a strip from it and bend it a little before glueing, best to use CA obviously! The metal siding is quite thick so you will most definately need to sand it a little.

that's what i thought. thanks for the suggestion! that should work like a charm. i most likely won't be able to try it until the weekend (swamped with work this week), but when i try it out i'll let you know.

Hi,

Maybe if you cut a slice off an old wine cork and pushed your large tubing onto it like a hole punch, thus blocking the end off and then carefully push the small tubing through the cork then paint?

gary

another awesome idea if chris's idea doesn't work or if i'm ever out of styrene. thanks gary!:cool: