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I decide to do a little project and make my own muffler! About this time last year i jump my car not on purpose. So i said to myself why not make one!!! here are some pics of what i got so far. i still need to run a pipe through it and pack it and finish welding but i think it will turn out. I will fill everyone in with updates.

Ummm...Is that galvanized HVAC ductwork you're welding together?

yes it is. I know its not right but this is just a mock up to see if i could do it. I am going to make it out of 16 gage cold rolled steal. i just need to figure out everything. Lets just say it wasnt easy to weld

letsridestreet wrote:yes it is. I know its not right but this is just a mock up to see if i could do it. I am going to make it out of 16 gage cold rolled steal. i just need to figure out everything. Lets just say it wasnt easy to weld

LOL, fair enough. I was afraid you were going to actually make a muffler out of it. Your lungs must hate you after welding that galvanized crap!

oh shit yeh i had the vents on full blast all this white shit floating around and stuff.

nice!

Interesting!

I like it. I've often thought about making my own twin tip muffler, since i cannot find any designs that I actually like and feel that they will perform as well as a mondo 3" ID melon shooter.

I know there are places to find some ceramic packing that will not burn out in less than a year. I don't know if you are trying to get that fancy though.

hey thanx guys!! i still dont know what i am going to do for packing. I just thought it would be cool when people ask where i bought the muffler! And i can say i built i thought that would be pretty cool

sounds like a great project keep us updated

I

just thought it would be cool when people ask where i bought the muffler! And i can say i built i thought that would be pretty cool

You may not see that day if you weld galvanized shit again!

Cool idea though,you are going to have to be thorough with your welds or it will probably leak.Other than that and the fact that it may not be worth it in the end i say press on and see how it works.I am also the type to spend time and money on silly things

Hey guys so i am almost done with the muffler went down to the local exhaust shop and they hooked me up with a roll of packing. I think the worst part of this whole thing was drilling like 300 holes in the pipe i have to run through it. All that's really left is to pack it and weld it up! I will have final pictures soon and pictures of it on the car!

Just to say it again folks: DO NOT WELD GALVINIZED STEEL!!! the zinc becomes an airborne toxic, and it can kill you!!! If it doesn't kill you it can make the rest of your life hell, medically.

Ive seen people weld galvanized on TV, they just held their breath. But they probably had good health insurance.

Interested to see how this sounds when it's on. I may have to do something like this myself whenever I get a garage...

tahiti350 wrote:Just to say it again folks: DO NOT WELD GALVINIZED STEEL!!! the zinc becomes an airborne toxic, and it can kill you!!! If it doesn't kill you it can make the rest of your life hell, medically.

It does become and airborne toxic, yes. Do people do it everyday? Yes. What about the guys who repair factory sheetmetal everyday?

gijonas wrote:Cool idea though,you are going to have to be thorough with your welds or it will probably leak.

Most factory and replcement mufflers have a drainage hole somewhere, usually near the back, so condensation doesn't rust it out from the inside.

Do people do it everyday? Yes. What about the guys who repair factory sheetmetal everyday?

What facory sheet metal is this??? And if someone is doing this they will probably either be taking to joe bornstein soon or they remove ALL galvanizing before welding.

Oh and some people punch there wives everyday,should we call it healthy??

gijonas wrote:

Oh and some people punch there wives everyday,should we call it healthy??

Wait...is that not okay?

The chemical that comes off of welding galv. steel actually condenses within a coupld of inches off the weld making it harmless...At my work some people that where welding it were freakin out so i called OSHA and its all good as long as you have the proper ventilation in the shop. However you could always just through a fan up so long as it doesnt blow away your shielding gas.

It's an old point to make now, but just one example of factory sheet metal that's galvanized is the BC/BJ Subaru Legacy.

The pictures, I not see them.