Muffler Fabrication & Design

[Erik G]

looks cool. I have been playing around with black widow mufflers on other cars, I don't think it will sound right on a vw for all the reasons JPaull mentioned, but some of the deflector designs (instead of "chambers" might interest you. Zero drone in my cars unlike flowmasters


https://www.blackwidowexhaust.com/

[evanfrucht]

[evanfrucht]

@Erik G

Thanks, I'm hoping it will sound good on it's own but I may add a smaller muffler behind this one I'm making. I have a 12" straight section after the collector which I can splice in a second muffler if I want to. If I do that I'm not sure if I should go with a straight through glass pack type thing, or a small 12" long chamber style muffler like the black widow.

I actually found out about the black widow muffler a while ago when I was doing the exhaust on my other car and I thought they were cool, but I ended up cheaping out and getting some flowmaster type knock off things.
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1967 Bug ( the daily rod )
1964 Fury Wagon ( the pavement shredder )

[Wreck]

something else that mufflers / exhaust can do if not right for the engine is cause tuning issues .
I had a 12" glass pack going to a tri flow muffler when I first got the car on the road . I couldn't get rid of a rich afr spike from 4000 to 4600 . removed the triflow and the spike went away . Yet on another mild engine I have, that combination works fine .

[evanfrucht]

[Wreck]

I have an afr gauge but I could also feel the power drop . Without the AFR gauge I would have been clueless to why . I spent along time modifying emulsion tubes etc before reading the trouble some have had with a CSP exhaust system , that started me looking at the exhaust .
AFR gauges are well worth the investment and will pay for themselves in fuel saving .

[evanfrucht]

Good to know. I will definitely think about getting one.
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1967 Bug ( the daily rod )
1964 Fury Wagon ( the pavement shredder )

[evanfrucht]

Ok, so the muffler is finished and exhaust tacked together. I will update this again once I finish the engine and will include more specifics and extra pictures in my built thread also. My music tech friend told me he will bring his expensive mics and recording equipment over so I can get a good sound sample.

I added brackets and had to add some dimpled sections to get it nice and tight up against the header. I also made support brackets for the muffler that attach to the header tubes. I just need to cut out holes and add the pea shooters. Also waiting on a second V-band clamp to actually attach the muffler. I will make a jig using an old stock exhaust I have to get the placement of the tips correct. I decided to go with a 2 inch exhaust tube diameter, I know it might seem small but I think it will be proper for the engine size. It's definitely not TOO big, which was one of my concerns initially. I feel this is a commonly overlooked factor when choosing exhaust size. IMO with too big of an exhaust diameter you will lose exhaust velocity... bigger is not always better is what I'm saying I guess

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1967 Bug ( the daily rod )
1964 Fury Wagon ( the pavement shredder )

[modok]

NICE, that's one of the finest apron cooker designs I've seen yet.
Definitely potential there.

[evanfrucht]

[67 Sunroof]

That’s badass man. I’m impressed. I wonder if you should’ve riveted the end of the metal in case you have to open it up and re pack it? Just a thought?
The inside was just too purdy hahaha
Where does it exit? To the left of the canister?
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1776cc, CB crank, CB 2241 cam, CB light lifters, CB H-beam rods, CB light flywheel, Mahle forged pistons, A1 Sidewinder exhaust, Dellorto drla 40’s, Hoover modded case, fully balanced, fully flowed, heads by www.type-emotorsports.com, Air ride suspension by https://www.airkewld.com/?Click=3989

[evanfrucht]

[67 Sunroof]

Oh yeah that’s right! I remember mentioning the hot dog type exhaust.
Yeah that turned out really nice! Good job
_________________
1776cc, CB crank, CB 2241 cam, CB light lifters, CB H-beam rods, CB light flywheel, Mahle forged pistons, A1 Sidewinder exhaust, Dellorto drla 40’s, Hoover modded case, fully balanced, fully flowed, heads by www.type-emotorsports.com, Air ride suspension by https://www.airkewld.com/?Click=3989

[[email protected]]

[evanfrucht]

I'm not one to let my doubts and uncertainty shy me away from doing something. I wanted to experiment with this. The comments about potential tuning issues remind me of the responses I get from my friends... "don't you NEED to buy those?" ... they never tried and write it off as impossible. A lot of people seem to just pick out some universal muffler and say "I like that one" and they bolt it on to their merged header or sidewinder. People rarely measure the back pressure and flow of these random generic mufflers to see how well they match their engines requirements. ALSO, much data can be calculated roughly using math anyway and backpressure and flow are two different things which are not related so simply. Exhaust velcocity (how quickly it flows and exits the exhaust) is also an important factor which was not mentioned, but I took it into consideration.

I was not impressed with the innards of the knock off Phat boy that came with this AA sidewinder, when I cut it upon it was basically just a glorified cherry bomb. Instead of buying one off the shelf that IS NOT even specifically made for these engine I tried to make one. No one made the exhaust I wanted, the way I wanted, so I built it MYSELF with my hands. I did do research on muffler design, and well... we will see how it works. I figure if I end up with some tuning issues I can investigate to see if it is the muffler. Everything will be attached with V band clamps which will make it easy to try something new or modify things.

I'm not the kind of guy to just pick out a bunch fancy parts from the catalog and bolt them together. The creative aspect is the real fun for me.
_________________
1967 Bug ( the daily rod )
1964 Fury Wagon ( the pavement shredder )

[[email protected]]

[c77owen]

I'm with Modok. I think it's great that you are doing this and I look forward to seeing how it performs and more so, how it sounds! Anyone can buy different mufflers and bolt them on over the counter headers, hell I've put three different mufflers on one of mine, before I decided on a sound, look, and performance that I was pleased with. I am curious what size tip(s) you are going to run and will you make it so that you can change the tip size for different sounds? Just a thought. Keep up the work, can't wait to hear it

[evanfrucht]

[evanfrucht]

[mark tucker]