How to DIY Stainless Steel Exhaust & mufflers?

[2 Fast 4 U]

I've been reading about exhaust diameters and there are a few numbers thrown around , 2", 2¼" & 2½", what should I use on a stock 2.0 N, that I can also use on a 2.2 E with a double barrel solex carb [thinking out loud in the future here: or two single barrel carbs, maybe even two double barrel carbs ].
I'm thinking of making a complete SS exhaust system for the Ascona, but I need [read want] to know: how, why, why not, what to use and what not, ect, ect, ect.
I've also read about 4" x 9" oval 11" mufflers what do they look like inside, and the same with the last round muffler?
Als reading somewhere making a oval 4"x9" by cutting a 4" pipe in half and welding two pieces of 5" to make the 9" complete.
How to connect the pieces shove them together or make flanges??

[baz]

erick whats your metal work skills base ?
working with SS is not easy , it does not bend as easy as mild steel it needs different gasses to use when welding it and filler wire if using mig or tig welding , the muffler needs to be made to cut noise without cutting flow
do you want to make an absorbant muffler or a reflective one ?

to make push and clamp fit you will need 2 sizes of pipe or an expander for the 1 size pipe (mucho euros ) to make flange ones you will need some 6 mm SS plate and a big drill bit
i used to make my own when i worked for a company called powerbend
but only because i had access to cnc benders , pipe plats a full MC shop and a workmate who used to work making custom exhausts so knew what to do inside a muffler
much easyer to get a one from a manufacturer there are loads around , i even found one that lists the GT and manta A in the UK
Double 'S' Exhausts - The Original and Finest Stainless Steel Exhausts Manufacturer in the South West of England, UK. We have been manufacturing quality stainless steel exhaust systems for over 25 years for performance and classic cars.

[heimue]

Buy your stainless steel exhaust from Welcome To MagnaFlow Performance Exhaust. They have everything you need and more...
Here is their direct link to universal mufflers: MagnaFlow Performance Exhaust - Universal Mufflers

Dieter

[tekenaar]

Originally Posted by 2 Fast 4 U Title: How to DIY Stainless Steal Exhaust & mufflers? I've been reading about exhaust diameters and there are a few numbers thrown around , 2", 2¼" & 2½", what should I use on a stock 2.0 N, that I can also use on a 2.2 E with a double barrel solex carb [thinking out loud in the future here: or two single barrel carbs, maybe even two double barrel carbs ]. I'm thinking of making a complete SS exhaust system for the Ascona, but I need [read want] to know: how, why, why not, what to use and what not, ect, ect, ect. I've also read about 4" x 9" oval 11" mufflers what do they look like inside, and the same with the last round muffler? Als reading somewhere making a oval 4"x9" by cutting a 4" pipe in half and welding two pieces of 5" to make the 9" complete. How to connect the pieces shove them together or make flanges??

. . . this means you don't want to be caught, right?! . . . DIY - self explanatory . . . stainless - no stain on your reputation, ergo not apprehended . . . steal - a little thievery going on perhaps?!

[2 Fast 4 U]

Originally Posted by tekenaar . . . this means you don't want to be caught, right?! . . . DIY - self explanatory . . . stainless - no stain on your reputation, ergo not apprehended . . . steal - a little thievery going on perhaps?!

a slip of the key and yes you're a "Cunning Linguist"

[2 Fast 4 U]

Originally Posted by baz Erick whats your metal work skills base ? working with SS is not easy , it does not bend as easy as mild steel it needs different gasses to use when welding it and filler wire if using mig or tig welding ,

I have some basic metal work skills, and what I don't know I can ask my co-workers at work for help, and yes I know that SS is a very difficult metal to work with.

Originally Posted by baz the muffler needs to be made to cut noise without cutting flow do you want to make an absorbant muffler or a reflective one?

what is the difference between the two?? I want a muffler system that is wisper quiet.

Originally Posted by baz to make push and clamp fit you will need 2 sizes of pipe or an expander for the 1 size pipe (mucho euros ) to make flange ones you will need some 6 mm SS plate and a big drill bit

Then I'll be making a flange type fitting, at work I can get the 6 mm SS, and about the drill, we have big ones but if not the correct size then I"ll have to drill the hole with a small drill along a circle line and file it to size

Originally Posted by baz i used to make my own when i worked for a company called powerbend but only because i had access to cnc benders,

I think I'll have to try and see what happens, would it work with a hydraulic pump bender?

Originally Posted by baz pipe plats a full MC shop and a workmate who used to work making custom exhausts so knew what to do inside a muffler

What does the inside of a muffler look like? I was thinking about drilling holes in the piece of pipe that is in the muffler.

Originally Posted by baz much easyer to get a one from a manufacturer there are loads around , i even found one that lists the GT and manta A in the UK Double 'S' Exhausts - The Original and Finest Stainless Steel Exhausts Manufacturer in the South West of England, UK. We have been manufacturing quality stainless steel exhaust systems for over 25 years for performance and classic cars.

I'll have to look in to that, thank you

[jordan]

what is the differance between the two?? I want a muffler system that is wisper quiet.

An absorbant muffler is one that will have some type of sound deadening material in a housing that the exhaust pipe goes through (that section of pipe must be louvered or perforated)

A reflective type muffler has a series of directional baffles that direct the exhaust sound frequency back at itself to cancel it out, in general it has been found that opels don't like that on account of decreased back pressure to the point that it is hurting performance.

I think I'll have to try and see what happens, would it work with a hydraulic pump bender?

hydraulic like any non mandrel pipe bender will likely just kink the pipe, especially stainless which has a high elastic yeild (lots of memory, over bend and then it springs back to get the desired angle) a trick that you can try is to fill the pipe with sand very tightly packed and seal both ends (don't know with what on this type of large scale) and it should help prevent it from kinking. I do this sometimes for tight bends in small aluminum fuel line.

What does the inside of a muffler look like? I was thinking about drilling holes in the piece of pipe that is in the muffler.

usually some type of fiber, blanket, brushes, and or baffles

[baz]

aaaaaaaaaarrrrrrrgggghhh i just spent 10 min typing out an answer to this and lost it when it would not post


gary can we have the old slow server that worked back please

oh and what jordan says


try Howstuffworks "How Mufflers Work"
for a vid on how they work

[2 Fast 4 U]

Originally Posted by baz aaaaaaaaaarrrrrrrgggghhh i just spent 10 min typing out an answer to this and lost it when it would not post gary can we have the old slow server that worked back please

well the same here I've typed it twice and it's gone I thought it was my PC making faults

[2 Fast 4 U]

Originally Posted by tekenaar Originally Posted by 2 Fast 4 U Title: How to DIY Stainless Steal Exhaust & mufflers? . . . this means you don't want to be caught, right?! . . . DIY - self explanatory . . . stainless - no stain on your reputation, ergo not apprehended . . . steal - a little thievery going on perhaps?!

Nope Nicely asked for it at the beer bottle filling plant today [], as if some one knew I needed SS pipe, so I toke a few meters home with me. They had two sizes:
#1: 50.8 mm [2.00"]OD, 48.2 mm [1.90"] ID
#2: 60.4 mm [2.38"]OD, 56.4 mm [2.22"] ID
Would size #1 work for the first part and size #2 for the part over the back axle??

I was thinking about making a flange on the piece where the two pipes from the manifold come together [the Y section] and go with SS from there

[2 Fast 4 U]

Originally Posted by baz oh and what jordan says try Howstuffworks "How Mufflers Work" for a vid on how they work

Very nice site, did up a few idea's thanks Baz

[2 Fast 4 U]

Originally Posted by heimue Buy your stainless steel exhaust from Welcome To MagnaFlow Performance Exhaust. They have everything you need and more... Here is their direct link to universal mufflers: MagnaFlow Performance Exhaust - Universal Mufflers Dieter

looked and couldn't find a match for me at the time I was looking, I'll take more time looking the next time thanks Dieter

[opelwasp]

If you want whisper quiet then Magnaflow is NOT the way to go. Über loud at times. The only way to get one that quiet is to find some stock muffler off of a grandma car. If you pick a large enough pipe it probily won't hurt performance much. Also using 14 AWG pipe will lower the sound a bit. Don't install a header they make lots of noise especially in the cabin.

[tekenaar]

Originally Posted by 2 Fast 4 U Nope Nicely asked for it at the beer bottle filling plant today [], as if some one knew I needed SS pipe, so I toke a few meters home with me. They had two sizes: #1: 50.8 mm [2.00"]OD, 48.2 mm [1.90"] ID #2: 60.4 mm [2.38"]OD, 56.4 mm [2.22"] ID Would size #1 work for the first part and size #2 for the part over the back axle?? I was thinking about making a flange on the piece where the two pipes from the manifold come together [the Y section] and go with SS from there

. . . hmmm, just what are you smoking here, Erick! Wow, have never seen a "few meters toke" before . . . thanks for the chuckle, Erick, but I think you meant 'took'.

"toke" is a 'reefer/MJ' cigarette . . . from the late '60s . . . even a song written about it . . . One Toke Over the Line - Brewer and Shipley (Lyrics and Chords)

[tekenaar]

Here's what I've used in the past depending on level of engine performance: 2" for stock or small performance upgrade - 1.9/2.0 stock or carb/street cam/ sprint/exhaust; 2.25" for high performance street - 1.9-2.4 cam/valves/SSD/DSD/FI/sprint/header/exhaust.

Remember, the idea is to keep exhaust velocity UP!! to maintain as much torque as possible in the mid-range RPMs . . . the single most important aspect for "street engines". None of us are in the 5500+RPM range often enough to justify anything else, methinks!

[2 Fast 4 U]

Well lets see what I've got:

sprint exhaust manifold,
stock double pipe between manifold and 1st muffler,

need to make:

#1 SS pipe [50.8 mm] from Y of double pipe to 1st muffler,
1 flange made of SS and 1 made of steel,
4"x9" oval x 11" muffler [or something similar],
pipe from 1st muffler over the back axle to 2nd muffler [#2 pipe 60.4 mm],
4" round muffler [or something similar],
end piece from 2nd muffler to the back of the car.

The front muffler wil be some thing like picture 1, [but with the out going pipe in the center] and the back like picture 2

[Paul]

You should consider the Dynomax UltraFlo mufflers.

[2 Fast 4 U]

Originally Posted by Paul You should consider the Dynomax UltraFlo mufflers.

Are they available in Europe??

[Paul]

I don't know, check their web site for distributors.

[tekenaar]

Originally Posted by 2 Fast 4 U Well lets see what I've got: sprint exhaust manifold, stock double pipe between manifold and 1st muffler, need to make: #1 SS pipe [50.8 mm] from Y of double pipe to 1st muffler, 1 flange made of SS and 1 made of steel, 4"x9" oval x 11" muffler [or something similar], pipe from 1st muffler over the back axle to 2nd muffler [#2 pipe 60.4 mm], 4" round muffler [or something similar], end piece from 2nd muffler to the back of the car. The front muffler wil be some thing like picture 1, [but with the out going pipe in the center] and the back like picture 2

Erick,
Don't think they make any "absorbing" oval mufflers with in and out pipes in the center, only baffled/reflecting types. I like using the centered pipe as the entry on the JCW mufflers I use and use the edge pipe as exhaust and oriented toward the outside of the car. This allows me to lean the "over axle" pipe toward the center of the car for extra clearance of the tilted GT shocks. Should give the same results with the other models.

[jordan]

Originally Posted by opelwasp If you want whisper quiet then Magnaflow is NOT the way to go. Über loud at times. The only way to get one that quiet is to find some stock muffler off of a grandma car. If you pick a large enough pipe it probily won't hurt performance much. Also using 14 AWG pipe will lower the sound a bit. Don't install a header they make lots of noise especially in the cabin.

I disagree on the magnaflow part, I have a magnaflow on my gt with an ansa resonator with 4 resonated tips and while it is not whisper quiet, it also isn't loud, at least I dont think it is.

[2 Fast 4 U]

Originally Posted by 2 Fast 4 U I'm thinking of making a complete SS exhaust system for the Ascona, but I need [read want] to know: how, why, why not, what to use and what not, ect, ect, ect. I've also read about 4" x 9" oval 11" mufflers what do they look like inside, and the same with the last round muffler? Als reading somewhere making a oval 4"x9" by cutting a 4" pipe in half and welding two pieces of 5" to make the 9" complete. How to connect the pieces shove them together or make flanges??

I think this part of my question has been answered enough but the following not:

Originally Posted by 2 Fast 4 U I've been reading about exhaust diameters and there are a few numbers thrown around , 2", 2¼" & 2½", what should I use on a stock 2.0 N, that I can also use on a 2.2 E with a double barrel solex carb [thinking out loud in the future here: or two single barrel carbs, maybe even two double barrel carbs].

Can I use the following size tubes??

#1: 50.8 mm [2.00"]OD, 48.2 mm [1.90"] ID, front pipe
#2: 60.4 mm [2.38"]OD, 56.4 mm [2.22"] ID, pipe over the rear axle

[tekenaar]

Originally Posted by 2 Fast 4 U I think this part of my question has been answered enough but the following not: Can I use the following size tubes?? #1: 50.8 mm [2.00"]OD, 48.2 mm [1.90"] ID, front pipe #2: 60.4 mm [2.38"]OD, 56.4 mm [2.22"] ID, pipe over the rear axle

You can certainly use those and maintain good exhaust velocity for both engines mentioned. Personally, I would use 2" pipe for the "over-axle" pipe as well, as there will be no discernible performance difference in the sub-5500RPM "street" range you'll be using . . . my opinion, anyway.

[RallyBob]

Originally Posted by tekenaar Personally, I would use 2" pipe for the "over-axle" pipe as well, as there will be no discernible performance difference in the sub-5500RPM "street" range you'll be using . . . my opinion, anyway.

I disagree with this statement based on my own testing. On a car with a shift point of 6000 rpms (stock hydraulic cam), with flat-tops, milled head, 38DGAS, ported intake, Sprint manifold and 2" main exhaust pipe...the larger 2.5" over-axle pipe was very noticeable throughout the power band. Even just off idle. I was given this idea by a tuner friend of mine in Sweden. In his testing on a rally car engine (2.5" main pipe and 3" over axle), he saw a 4-6 hp increase throughout the power band. Obviously less at lower rpms but more on the top end.

Granted, this was on a Manta, so the axle pipe has to take a 90 degree turn up, then 180 degrees over the axle, then another 90 degrees into the rear resonator (360 degrees worth of turns in 18"!). Even though the diameter is larger the velocity gets killed climbing over the rear axle and making those turns, so the larger pipe keeps up the exhaust gas speeds.

This was with two mufflers, a small 2" inlet/outlet oval body before the axle, and a 5" diameter round body (2" inlet/outlet) behind the rear axle. I also tested the exact same combo with a pair of 2.5" mufflers (same 2" primary tube however), and in that instance I felt I lost low end power but gained mid-top end power. It was also 4 db louder, although the same brand and externally dimensioned mufflers were used. The bigger diameter obviously has different accoustic values.

Bob

[2 Fast 4 U]

@ Rally Bob:

If I understand you correctly: use the 50.8 mm [2.00"]OD, 48.2 mm [1.90"] ID pipe,for the front pipe and going in the 1st muffler and use the 60.4 mm [2.38"]OD, 56.4 mm [2.22"] ID pipe for over the rear axle.
And for the 1st muffler the 50.8 mm in and 60.4 out with a size of 4" x 9" oval x 11" length, and the second muffler Ø 5", 60.4 in and out.
And about the rear axle try to make the bend as shallow as possible.
Is this some what close to what you were saying???