Making a can of a muffler for a motorcycle. Improving the appearance of the scooter muffler Two-stroke and four-stroke scooter

Hello.

After several loud shouts of "kurvaaaa !!!" with a motorcycle zapulivaniya in the branches of trees, the muffler on the poor TM EN 300 ... crumpled 🙂 I had to make a new one.

I would never have mastered such a job. Except for minor manipulations, such as burning a flute and traveling for materials, the new muffler can was completely made by Oleg, for which another huge thanks to him!

A muffler is one of the most common motorcycle tuning options. A logical question: why, besides the banal saving of money, bother with making a copy of the stock glushak, when you can order a tuned one, at the same time strangling the release a little. The fact is that the tuning of the release on two-stroke motorcycles should be started, first of all, with the resonator. And then, to the resonator, which are selected for the desired operating speed range, select a muffler bank. Or not to pick it up, since it does not have such an effect on two-strokes, as on 4t. Therefore, ordering a tuned can of a muffler without tuning the resonator does not make sense, and ordering a stock is doubly meaningless. There is one more factor in order not to order FMF, Yoshka and similar products: there is so much foolishness in a two-stroke three hundred that, for example, I will not need to increase it additionally for many years 🙂

The original muffler on TM EN 300 is made of foil, crumples perfectly, bent after another fall, starts to cling to the wheel when landing from jumps, when the suspension compresses - and wipes to holes!

Therefore, having sacrificed a little weight savings, a new muffler had to be made from an aluminum pipe 3 mm thick.

The pipe, however, was found with a diameter of only 100 mm, while in order to maintain the original proportions, the diameter of the pipe had to be 90 mm.

In parallel, I burned the flute. As it turned out, you don't even need a burner for this, a 400-degree hair dryer will do just fine.

In addition to saving motorcycle weight, no manufacturer will install mufflers with a 3 mm wall, or at least with 3 mm brackets for attaching to a subframe, on their motorcycles, since then this can will never break in its life, and the cost of materials will increase ...

The neat, scaly weld will be angled down towards the ground and will not be conspicuous. It was the turn to make a plug made of 3 mm aluminum sheet. Then a tube will be welded into it, which will center and fix the flute from the inside.

Hello everyone!
A small topic on the construction of a muffler "directly". An example is based on a moped, but it is no different from a car one. To do everything really on the "knee" with a mallet in the barn, you just need to order a couple of parts to a familiar drunk turner and find a piece of stainless steel. I have a native factory close at hand, where I have round-the-clock access to metals of various brands and machines. In the beginning we measure out which jar will be in size. The diameter is multiplied by 3.14 and we get, respectively, the length of the circle in unfolded form. The diameter of mine is like 96mm and the height of the can is 400mm. it is better to take it in a film, for which you yourself will understand, but it will work without a film. We make a flat pipe and weld with spot welding.

Then the turner (I sharpened myself) turned 2 washers for us to the desired diameter.

And what is the film on the pipe for? For the inscriptions, of course!) For myself, I skimmed the Pasan pontovoy inscription ZiD Sport.

If there is no film, you can stick a wide electrical tape. First we print the inscription on the printer, then glue it to the pipe and cut it with a scalp or special. Then he carefully removes the elements we don't need and voila, the stencil is ready.




We rejoice at the received inscription


Next, you need to make a pipe of the required diameter from a mesh or lattice with cells with a finger inside the muffler.


We insert all this so that the holes coincide with this pipe, we fill tightly around the edges with cotton wool such as Ursa or Knauf (these are building heaters) Such wool can withstand a high enough temperature and does not fly out of the pipe due to the mesh inside. The middle remains completely free even if by shining a flashlight there, we will see the branch pipe even)
That's all, I got it all for free.

What is a muffler and what is it for? The goal is to acquaint you not only with how to design a homemade scooter muffler with your own hands, but also with what the purpose of this important unit is.

Two-stroke and four-stroke scooter

A scooter, as you know, can be with a two-stroke or a four-stroke engine. The principle of operation of the entire exhaust system for analogs differs radically.

A muffler on a four-stroke scooter removes gases in a relatively shorter time, doing so with minimal noise. In addition, tuning the muffler in this case will be quite simple. On the other hand, in both cases, when carrying out tuning, it will be necessary to change the pipes.

For a muffler of a two-stroke scooter, it will be much more difficult to select components that make it possible to carry out tuning. The regular muffler for such scooters is more difficult to manufacture and configure.

The exhaust system of a two-stroke scooter works as follows. During the exhaust gas cleaning process, some of the power is returned to the engine. This happens at certain speeds and if you manage to implement this whole process, after tuning, the scooter will not be recognized.

You can install a high-quality and properly tuned resonator on a push-pull scooter. This will give a noticeable increase in dynamics up to a quarter. But in this case, it will be relevant to carry out professional settings for the entire power system.

What are quality mufflers for?

As you know, a certain amount of fuel combustion products is collected in the cylinders of a moped engine. They must be thrown away, and in this case it is the muffler that is responsible for this. In other words, this unit, as it were, smooths out the pulsations that are inevitable when exhausting combustion products at high speed.

The very design of the muffler, which is used not only on scooters and mopeds, but also on motorcycles and cars, implies a special exhaust system, which can be different, depending on what result the owner of the vehicle wants to get. For example, if the desire to improve the gas outlet system is associated with an increase in the power of the scooter, a special type of muffler is needed - a direct-flow one.

Direct flow type muffler

Installation of this type of muffler will entail not only an increase in dynamic power, but also significantly increase the noise emitted when gases are emitted. On the one hand, this is good, because this way you can attract the attention of other drivers, thereby increasing passive safety. As you know, drivers of large cars often complain that they do not notice motorcyclists, and even mopeds and scooters, even more so.

It is not difficult to make such a muffler from scratch or with a tuning method, but there are many technical aspects to be learned.

Features of a straight-through muffler

The features of the direct flow are as follows: the exhaust gases are thrown out of the engine immediately, the cylinders of the power unit have time to be filled with the fuel mixture in the optimal amount.

I would like to remind all readers that at the moments of intake and exhaust, engine valves tend to open and close. Between these stages, a vacuum occurs, which allows you to clean the cylinders of exhaust gases. As a result, free space is freed up, where the fuel mixture is supplied. It is easy to guess that the faster the cylinders are freed from the production, the faster they will fill.

Thus, if you can ensure a faster escape of gases from the system, the productivity and, as a result, the power of the scooter or moped will increase.

Cleaning the muffler

Before starting to change anything in the exhaust system, I would like to give one piece of advice. The power of the scooter is directly affected by the cleanliness of the muffler. If it was possible to see the working off in the cut of the muffler, the owner of the scooter would be very surprised. After a certain mileage, the dynamics of the scooter decreases, and the owners begin to look for the reasons for this, finding them in a complete alteration of the standard muffler or its replacement.

The reason for the loss of power, however, may be hidden in the state of the engine itself. This will help determine the specialist who should be contacted before tuning. But the most common reason for the loss of dynamics is soot, which clogs the muffler. Cleaning in this case is recommended in three ways.

Method one: mechanical

It involves cleaning in the cut of the muffler (it is done with a grinder). A wire or cable is used to clean the inside of the muffler from soot. The section is closed by welding.

Method two: chemical

It involves pouring water with some kind of purifier into the muffler. For example, caustic soda is suitable for this purpose. There is an advantage with such cleaning: the appearance of the muffler will not be affected in any way.

Third way: heat treatment

The muffler is heated either on a scooter with a blowtorch, or dismantled in a furnace or on a grill. It will be necessary to repaint the muffler only after cooling down.

Modification of the muffler

As a rule, many craftsmen do not just assemble a muffler, but alter a regular one. This makes it possible to spend less time and get a more acceptable option.

Tools and materials

Before you start tuning, you need to prepare the necessary tools. In this case, the following components will be needed:

1. Welding machine, preferably with different operating modes;
2. Pipe of appropriate size and diameter;
3. Bulgarian;
4. Metal dishwashing brushes in the amount of several pieces.

We start tuning

First, dismantle the muffler. Then we take a grinder and cut out a piece of metal on top of the muffler. In such a cut, it will be much easier to work with a muffler. You should almost completely cut out the top. After that, it is necessary to clean the entire inner space of the muffler, carrying out the dismantling of the elements that are in the cut.

It's time to work with the piece of pipe that we have prepared. Using a powerful drill or welding, we make many holes in the pipe. We place the pipe in the cut of the standard muffler. We select in advance a pipe of such a diameter that it fits inside the standard one. It is desirable that the pipe be free of any obvious flaws and perfectly flat.

The space in the cut that remains between the two pipes must be filled with metal brushes or similar materials. We weld the top of the pipe, as it was. We mount back all structural elements that were dismantled in the process.

As a result, given by the tuning, we will have a forward flow muffler that provides the desired result. The massive and luscious roar of the engine, as well as the increase in the power of the moped, will be evidence that everything went well.

Making a straight-through muffler from scratch

You can make such a muffler from scratch. It will be a completely new variant made from several components. The tricky part of this operation, called tuning from scratch, is finding the exhaust system for a particular moped.

Tools and materials

In this case, again, you need to prepare the necessary tools and materials.

1. Purchase from a store or find two pipes with a diameter of 33 mm;
2. Buy plexiglass;
3. Bolts М8 and М3;
4. We prepare glue and nails;
5. Welding machine;
6. Needle files;
7. Hacksaw for metal.

Let's start assembling

First of all, you need to cut 18 cm from one of the pipes. It is recommended to carefully process the place in the cut with a file. Cut a circle from the second pipe with a diameter of 1.5 cm. We process it using the above method. We glue the cut out circle in the cut of the first pipe. We cut off another piece of pipe, 18 cm long. We make many holes in it. This can also be done with a sharp nail.

We connect all the parts using a welding machine. We fill the cavity formed at the junction of two pieces of pipe with mineral wool. We wrap the finished product with a special fire-resistant material. The homemade muffler is ready. To install it, you will need to attach the element to the attachment of the scooter body.

We make a muffler attachment element

From plexiglass, which is indispensable in this matter in view of its strength and easy coloring, we cut out a special type of ring, the edges of which can be unbent outward by 180 degrees. We attach the resulting circles with serifs to the moped using the bolts needed. We polish the muffler with sandpaper. The joints of the homemade product with the body of the moped will need to be lubricated for fidelity.

If homemade production causes certain difficulties, you can find a lot of models of mufflers already ready-made. They are usually inexpensive. On the other hand, only a home-made version is able to give the perfectly expected version.

A muffler on a motorcycle is a device that dampens the sound of an engine. Mufflers are needed not so much to reduce noise as to change the tone. And high-frequency sounds affect the psyche and ear of a person more unpleasantly than low tones.

Many people associate the roar of sports motorcycles with a muffler. And they believe that the filling of the muffler can reduce the power of the car. But this is not the case. When replacing or redesigning a muffler, only a small amount of horsepower is lost.

There is an intake and exhaust muffler. And scientific research has proven that by choosing the right key elements, the filling of the cylinder can be improved. Such mufflers are called resonant mufflers.

The part of the muffler located behind the first partition is engaged in noise suppression, and it consists of an acoustic filter. These filters are simpler on sport bikes, since a higher noise level is allowed in sport bikes.

When deciding to redesign a muffler, keep in mind the following. Sometimes, when improving one part, you have to sacrifice the quality of another. No one has yet succeeded in creating a universal motorcycle.

Manufacturers recommend using factory-made motorcycle mufflers. The muffler cavity is covered with carbon deposits, which can close the channels of the acoustic filter. Therefore, the cavity of the device must be cleaned regularly. Carbon deposits impede the escape of exhaust gases and reduce engine power. The mufflers must be cleaned after every five to ten thousand kilometers.

The original mufflers are quite quiet and good. Their disadvantage is their heavy weight and size. Many also consider their high price to be a disadvantage. Mufflers are manufactured by many companies, and you can use a non-native muffler if you wish. Most often these are open mufflers. In them, the exhaust gases leave the engine without any obstruction. But they make a lot of noise.

Fans of a loud roar of motorcycles can buy the cheapest muffler, which does not muffle anything. But if the roar of the motorcycle does not suit you, then you will have to buy an expensive option.

Such mufflers differ in design and material of manufacture. There are four types of them:

• Titanium. He is considered the best. It's lightweight, nice looking, and not very hot.
• Aluminum. Light enough. Looks worse than titanium, but there is a drawback. You can get badly burned.
• Carbon fiber. Looks nice, light and cold. But its significant drawback is that even with vibrations, it can crumble.
• Stainless steel. Strong and heavy, but very hot.

Each type of muffler has its own advantages and disadvantages. Therefore, you have to choose for yourself.

You can buy a straight-through muffler at any specialized store. Usually they are interested in young motorcyclists who dream of high speeds. But real bikers are not bribed by famous brand stickers. They do everything they need with their own hands.

If you have a desire to enter the world for real men, you need to make a direct-flow muffler with your own hands. When riding at normal speed, its noise will not differ from other motorcycles. But with an increase in speed, the characteristic roar of the engine appears.
What do I need to do?

• A piece of pipe is taken, which has a diameter of 60 mm, and is cut in half. First, one piece is machined and a flange is welded in the middle. The outer part does not change. This is the inlet. In the half of the pipe, which will be located in the muffler, you need to drill a large number of holes with an electric drill. You need to use a drill of 5-6 mm. Sink the flange with a ten millimeter tip into a pipe with a diameter of 100 mm and weld it on.
• We are preparing the second pipe. Weld the flange to the second pipe section. It should be 80 mm from the edge. This part of the pipe will be inserted into the muffler.
• In a pipe with a diameter of 100 mm, carefully lay out mineral wool insulation. This is to combat noise reduction. To do this, roll up the cotton wool along the diameter of the pipe and push it to the opposite side.
• Roll up the mesh and lower it inside the insulation that was inserted into the pipe. The mesh should slide over the perforated nipple.
• Now you need to insert a flange with a pipe that was prepared in advance into the pipe with the short end. It must be sunk 10 mm deep and welded.
• From the old muffler, you can cut off the fastening elements and transfer them to the straight-through muffler by welding them.

Why do motorcyclists need direct flow to a motorcycle

The exhaust system is designed to perform several tasks. Exhaust gases are discharged. The exhaust gas outlet fills the engine cylinders better. And extinguishes the noises. The spent mixture is ejected from the cylinders at a very high speed and therefore a loud noise is generated. It is the muffler that reduces the noise of the exhaust gases due to the obstacles arranged in it.

A straight-through muffler simply does not have baffles that reduce noise. In this case, the exhaust gases escape without obstruction, and the engine power is increased. Therefore, the noise on such motorcycles is like a roar.

A straight-through muffler or a straight-through to a motorcycle emits a kind of engine roar and is not accepted by many people. It is believed that motorcycles with such a silencer disturb people and pollute the atmosphere.

Motorcyclists who advocate quiet city driving do not accept straight-through mufflers. But experienced bikers are sure that forward flow is not only passive safety, but even active safety on the roads. How? The fact that you can designate your location in the stream of cars.

Sometimes it is difficult even with a signal or headlights to show some drivers that you are nearby. And only the roar of the muffler helps to do this. And it happens that the sound of the muffler stops the driver from a careless maneuver that could lead to an accident.

It is difficult to imagine a sports or tuning city car without a straight-through muffler. The noble roar of the engine pleases the keen ear of the owner, thrills the girls, arouses the envy and admiration of friends. However, neighbors do not always like this, and the traffic police prefers a quiet forward flow. This is where the driver faces the question: what to do to muffle it, what methods are used to make the exhaust quieter.

Why is forward flow needed and why sometimes it needs to be muted

A car with an exhaust louder than 96 dB will not be able to pass a technical inspection and will not cross the border - in Europe, the traffic rules are strict, and the police are incorruptible. Even in motorsport, the sound is limited. Only Formula 1 promoters do not like the attempt to drown out the noises from cars. They even opposed new regulations for switching from eight-cylinder engines to V6, fearing for the prestige of racing.

Having conceived to muffle the forward flow with your own hands, you need to clearly understand the principles of the coordinated release, and determine the purpose of the car tuning performed. The improvement in dynamic performance is only due to the installation of a new "spider" - the exhaust manifold. The rest of the components of the exhaust system simply should not create resistance to gases and have a bad effect on the result.

When properly tuned, the resonant exhaust gives a 3-9% increase in torque for naturally aspirated engines, and more than 10% for turbocharged engines. But in production cars, the increase in the rate of filling the cylinders with the working mixture during modernization is less than 2-3%.

Installing a straight-through muffler on conventional stock cars is needed only as a decorative option for a pleasant exhaust tone. The main criterion for the quality of the direct flow on a serial machine is the euphony and velvety noise of the engine, and not the increase in power. The car will shout louder or quieter - this will not affect the speed and dynamic characteristics. In this case, when there is an urgent need to drown the forward flow, you can do this without thinking about the consequences.

What is a flute in a straight-through muffler, and what is the effect of it

To make the forward flow quieter and to get "through" decibels at the output, a simple design is used, which motorists call a flute. This is a piece of perforated pipe 180–250 mm long and a little more than 1/3 of the exhaust diameter, with a welded washer-plug in the form of a disk, cylinder or cone, which is bolted inside the forward flow, at the air cut, thereby allowing it to be muffled.

The principle of operation of a flute for direct flow is that when the cross-section of the exhaust channel changes, and the exhaust gases exit through the perforations, the following occurs:

• change in speed and pressure;
• the sound wave breaks;
• the volume is reduced by 3-4 dB, the exhaust becomes quieter.

The correct name for this flute is silencer, and it comes with expensive exhaust systems sold online. You can also purchase separately, the average price of good European models is 70–150 dollars, and mass ones from the Middle Kingdom - from 450 rubles.

Do-it-yourself flute for forward flow

If you have the desire and skill, then making a flute with your own hands in order to drown out the forward flow is not difficult at all. It will turn out to be cheaper than a branded one, but not always better than a Chinese one.

For work, you need a steel (preferably stainless) pipe 20 mm and a piece of sheet metal 0.8–1.2 mm thick. It is desirable to cook by arc welding, observing the rules for working with stainless steel. A plug pre-bent from a sheet of steel with holes for fastening is welded to the pipe. It can be screwed on with three M8 screws, but for installation in a few minutes, one threaded connection is enough.

When manufacturing, you need to try to accurately measure the inner diameter of the muffler at the air cut, so that the plug fits loosely, but without a gap. Then, when entering the track, you can quickly remove the flute from the hot pipe with a pair of wrenches or pliers.

It is important to remember that any obstruction in the exhaust pipe, including the silencer, will inevitably reduce engine power. It is definitely not possible to make it quieter and dim it without loss.

To make a quiet straight-through muffler, but not to lose the additional power that is provided by the modernization of the exhaust tract, a forward-flow damper is used. This exhaust design has been known for a long time and is found in many BMW models (more often with a manual transmission).

When the engine is running at low power, when the advantage of the coordinated exhaust is not used, the exhaust gases exit through a conventional muffler, and the direct-flow one is closed by a damper. At optimal speeds, the damper opens the outlet to direct flow, and the engine delivers maximum torque due to enhanced ventilation of the cylinders.

The damper control is automatic, but there are also manual models. In the city, such a car almost does not differ from a stock car in sound, and on the highway it not only sounds like a tuning car, but has a real increase in power. It is not cheap - for a full machine gun, complete with a titanium "spider", the price often exceeds a couple of thousand dollars.

Similar in capabilities, but not very famous counterparts are moderately priced, but it is better to select the appropriate option with a specialist - for the success of such an upgrade, the knowledge of a mechanic engineer may be required.

The budget option of a forward flow with a damper can also be welded independently from scrap materials. The upper part of the old carburetor is suitable for the damper, if you bring the idle cable into the salon. Making such a structure with your own hands, it will take much more effort and time than for a homemade flute, and the result of the installation cannot be predicted in advance. Muting the sound is easy, but to conserve power, even if you're lucky, you have to tinker with the tuning.

Output

Whichever option you choose to muffle the exhaust, it should be understood that you can just buy a ready-made solution if finances allow, or you can muffle it yourself by making a device from improvised means.