How To Scratch Build Mufflers

There are many ways you can create Mufflers, but the big question is "is it too big?"

Here is my writeup on how to create mufflers without going overboard on size, or making it too small.

Tools/Supplies
- 1 piece of 5/32" stylene tube
- 1 piece of 7/32" stylene tube
- Modeling glue
- Round and flat files (or sandpaper)
- 1/8" drill bit or hobby knife
- Wire cutter or tube cutter (to slice pipes)
- Marker
- Silver (or other preffered) paint
- Bottle of patience and time

When you remove the tubes out of the package and lay them next to each other, it should look something like this:

The 5/32" tube should easily fit right into the 7/32" tube,

But as you can see, the border between the "outer" and "inner" hole of the 5/32' tube is large, and doesn't really look realistic,

So by using the 1/8" drill bit by either hand or a Dremel on it's LOWEST speed, drill it through, to widen the "inner" hole, or you can use a hobby knife to carve it, just make sure you carve evenly.
Then you use the round file to smoothen things out, it's hard to tell from the pic, but the hold did come larger.

Then you want to cut the desired length for the inner tube (5/32"), for this example, it was cut to about 13/16". I also cut the outer tube (7/32") about 11/16' leaving about 1/8" for the tip, but remember, it's going to VARY from car to car.

And remeber to smoothen out the parts you just cut with a file, or sandpaper.

Remember that the inner tube has to be longer.

Now you can test fit the two pieces, making the back flush, if it's a little too long, you can file it, etc.

Now, you want to glue down the two pieces, do this using your prefferd glue.
*NOTE+TIP* Apply the glue on the inside of the 7/32" tube and insert the inner tube 5/32" back end first, and rotate the 5/32" tube so glue touches almost every spot.

Let that dry, then paint it with your preffered color (Silver/Chrome, Carbon-fiber, Fire-red. etc)
*TIP* While painting, avoid breathing in any paint fumes, for this is a health hazard!

After you let the paint dry, after waiting a long time, take a good look at it! Because now you're done with the muffler! Congrats too you, now all you have to do is make the exhaust pipes!

Here is mock up pics on a supra! (I'll dry to get less blury pics, it's the lighting!)

As you see from the pics, it's not too big, or too small, it's what I call perfect!

JDMF © 2003