Securing baffles

[Sharp64]

Running a set of bazookas with baffles. The problem is the damn things keep coming out!! First attempt was using screws. Lost one within a few miles. Second attempt was trying pop rivets. One lasted 5-6 miles, the second one maybe 20-30 miles. Last one to come out still had the ball side of the pin still attached on both rivets. Heads were sheered clear off. Short of getting them tack welded into place what are my options? Non-aluminum rivets? Nuts and bolts? JB Weld?
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1960 Indigo Blue Ragtop (Blue Barry)
1967 Ghia
1985 Westy Money Pit
“...some men aren't looking for anything logical, like money. They can't be bought, bullied, reasoned, or negotiated with. Some men just want to watch the world burn.” - Michael Caine

[Dale M.]

Get rid of them, get 4 into 1 exhaust and get bonus by a gain of some horse power.... Other option may be 1/4-20 bolt all the way through and use locking nut...

Dale
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"Joe Pody Sandrover" Buggy with 2180 for Autocross (Sold)
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All suggestions and advice are purely my own opinion. You are free to ignore them if you wish ...

[Sharp64]

Wondered how many posts before I got that one. Thanks for not letting me down. Had a 4-1 and didn’t like it. Let’s leave it at that and keep on topic.
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1960 Indigo Blue Ragtop (Blue Barry)
1967 Ghia
1985 Westy Money Pit
“...some men aren't looking for anything logical, like money. They can't be bought, bullied, reasoned, or negotiated with. Some men just want to watch the world burn.” - Michael Caine

[vwracerdave]

Keep them. I don't care what the haters say about dual cannons. I think they are the coolest looking exhaust there is for a Dunebuggy. Yes you will give up some performance but your engine will still run. They are fine for smaller engines up to around 90 HP, then they become too small. I ran duals for many years on my 1756cc and enjoyed them. Thousands of street miles and hundreds of 1/4 mile passes.

I ended up welding mine in after the duals started showing a little rust around the edged. If I were to try it again I think I would use about 3 stainless steel button head machine screws with nuts, or try to find some stainless steel rivets.
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[Sharp64]

What’s sad is I really like them without the baffles, but it gets a bit loud with the wife in the buggy. I found some SS rivets online so may try that. So far two baffles got toasted as someone ran over them. The last came out and I was able to grab it before it got run over and should be able to straighten it out.
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1960 Indigo Blue Ragtop (Blue Barry)
1967 Ghia
1985 Westy Money Pit
“...some men aren't looking for anything logical, like money. They can't be bought, bullied, reasoned, or negotiated with. Some men just want to watch the world burn.” - Michael Caine

[YDBD]

Through bolt them all the way with metal lock nuts? Or stainless steel rivets, extra long?

My dad ran dual cannons only on our buggy in the '70's, the look is cool and are about the same as the original Thing mufflers that tuck under and come out the bumper. I don't care for the sound while driving...
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'56 pan Dune Buggy since '69
don't live in the past...but when I did:
'67 bug
'64 baja
'60 dune buggy
'73 Personenkraftwagen Type 182 "Thing"

[Sharp64]

I missed the parts where I asked anyone's opinion whether they liked them or not...

Seriously guys, while I appreciate the info on how to better secure these, it's really unnecessary to add the quips about how you lose HP or don't like the sound. I bought them, I like them, I just need to secure the baffles better to make the wife happy.

Thanks again for the suggestions, think I have my answers.
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1960 Indigo Blue Ragtop (Blue Barry)
1967 Ghia
1985 Westy Money Pit
“...some men aren't looking for anything logical, like money. They can't be bought, bullied, reasoned, or negotiated with. Some men just want to watch the world burn.” - Michael Caine

[bigfatloser]

Every post has had a suggestion.....

Pick up a copy of "How to win friends & influence people ?
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[Sharp64]

[GS guy]

I don't think a rivet would last - unless it was solid SS (or steel) and peened over aircraft style.
A SS allen-pan head with steel deformed-style locking nut would probably work (and look) the best. With a couple of small OD SS washers to finish it off. The vibration will likely kill anything after a while - keep an eye on them.

I'm in the "quieter" exhaust camp too - I like some sound, but any kind of tight exhaust system as on the back of a buggy will tend to be easier to make louder vs. quieter.

I've never heard one, but I'm guessing the adapted Suzuki Hayabusa cans in place of the standard bazookas would give a nice note.
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70's vintage Deserter GS buggy - undergoing transformation to Super GS!

[monomanx]

I changed out my VW engine for a 140 HP corvair engine earlier this year. Headers are limited for these engines. I ended up purchasing some Clarks corvairs Dual cannon/trumpets as well as their baffles.

They recommended using 1/4-20 bolts through the entire set up to hold the baffles in. I could not bring myself to do that. I opted instead for SS pop rivets. One per side at the 5 or 7 position.

So far I have about 5000 miles on the engine with no visible or mechanical issues with the pop rivet. That is NOT to say that it could become an issue.

Re the Hyabusa exhaust, my buddy also has a corvair engine. He has some aftermarket mufflers (some motorcycle type) mounted to his duals. They sound much deeper and throaty.

See the images attached. You cannot see the baffles but you can see the diameter of the muffler portion.

[joescoolcustoms]

I too have used the Stainless Steel Rivets. I use three per side. Have lasted 10 years so far.

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Best Day Ever Racing 2022 NORRA 1000 2nd in Class and first All Female team to complete the race

Everyone is gifted. Some just do not open the package.

Looks like it was painted with a live chicken,polished with a brick and buffed with a pine cone

[Sharp64]

Thank you guys. I’ll pick up a pack of SS rivets. Currently have two holes per side but may step up to 4/side. I had thought about a through bolt or what but that’s a damn big hole. As it is I cringed drilling the existing holes on a fresh out of the box set of pipes.

Went for a drive yesterday without the baffles and seriously I really like the sound. I’m not an attention whore, but a bright red buggy with loud pipes gurgling was pretty fun I must say. Watched 2-3 guys roll down their windows as they approached with big grins on their faces. Good times.

Any more pics of the grey buggy Joe? You seriously seem to have some nice ones. I’m thinking about satin grey or black plasti dip at some point when I cut the hood open until I can work up the courage or money for real paint.
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1960 Indigo Blue Ragtop (Blue Barry)
1967 Ghia
1985 Westy Money Pit
“...some men aren't looking for anything logical, like money. They can't be bought, bullied, reasoned, or negotiated with. Some men just want to watch the world burn.” - Michael Caine

[andk5591]

With fasteners...Size matters. When we ran dual canons on the buggy, Just used sheet metal screws. Don't remember the size, but obviously what you are using is too small and/or not enough of them. I think I used three screws per side.

And totally agree that dual canons look the best. If you don't mind the power loss, then have fun. After playing with a couple different ones (performance/looks trade offs) I opted for a 1 3/8" U bend and a Super trapp....

Baffles themselves where part of my issue with the canons. I used glass wrapped, but the packing would blow out after a few months. Started just buying glass mats from a motorcycle shop.
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There's more, but not keeping them...

[oprn]

My Buggy came with dual cannons and I truly do miss the "pair of badly tuned Harley Davidson" sound and the authentic looks. I do not miss the volume though on the highway as it becomes totally unbearable on long trips. Your wife is right in that the cannons as they come are only tolerable for shots blasts around town, then let your ear drums have a rest and stop bleeding!

I am presently looking for a way to put those mufflers back up there beside the tires where they belong and still retain the advantages if a 4 into 1 system. Maybe go forward with the pipes, flat collector under the transaxle and split with duals back in the wheel wells?

I hate the looks if the "bag of snakes" Baja systems most guys use and can't imagine trying to reach around those hot pipes to work on the engine!

[Sharp64]

S&S used to make a nice system that was IIRC 4-1 system but instead of sticking up square in the middle of the back of the engine where you burn the shit out of yourself trying to set the timing or adjust anything, the pipes curled towards the front of the buggy and then curved back towards the back like Bazookas. They were the rage in the late 80's (at least in the magazines) You saw them mostly on full bodied cars, but I would love a set on the buggy. Unfortunately, they no long make them and I don't feel like spending what I'm guessing would be a grand or more having them custom made and ceramic coated.

Either way, not the point of this thread. I'm trying the SS rivets and maybe drilling two more holes on each pipe so that there are 4 holding each baffle IF I put them back in. They may magically end up discontinued....
_________________
1960 Indigo Blue Ragtop (Blue Barry)
1967 Ghia
1985 Westy Money Pit
“...some men aren't looking for anything logical, like money. They can't be bought, bullied, reasoned, or negotiated with. Some men just want to watch the world burn.” - Michael Caine

[joescoolcustoms]

[Sharp64]

[andygere]

Stainless steel pop rivets are incredibly strong and should hold the baffles in as others have stated. They are, however, somewhat difficult to properly install with the typical pop rivet gun. If you don't have a professional type tool, or better yet a pneumatic riveter, see if you can get your hands on one. If you think your tool may be up to the task, do a few tests on scrap material of similar thickness to be sure. If you get one only partially popped before the "nail" breaks off, it can be hard to remove without enlarging the holes and ruining the part. The nice thing about the rivets is they will me much less noticeable vs. bolts or sheet metal screws.

[Sharp64]

Good info, thanks. I found a heavier duty rivet tool, so may grab that. I have some other projects that SS rivets would work well for now that I know they exist. lol.
_________________
1960 Indigo Blue Ragtop (Blue Barry)
1967 Ghia
1985 Westy Money Pit
“...some men aren't looking for anything logical, like money. They can't be bought, bullied, reasoned, or negotiated with. Some men just want to watch the world burn.” - Michael Caine