How to make an effective muffler for a motorcycle engine

The noise produced by a motorcycle engine at high speeds, especially two-stroke engines, is very unpleasant to the human ear due to its harshness and high pitch. But it can be noticeably reduced with the help of a homemade muffler and this will not require large expenses, scarce materials, special knowledge and skills.

Will need

Materials:

steel pipes and fittings;
conical pipe plugs;
metal fine mesh;
soft knitting wire;
plastic clamps;
mineral wool;
steel bends for welding.

Tools: metal cutting saw, drill, vice, semi-automatic welding machine, metal scissors, hammer, manual riveter.

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The process of manufacturing a motorcycle muffler from available and inexpensive materials

We will need two pipe blanks: a short one with a large diameter, and a longer one with a smaller diameter.

We cut one thinner end of the workpiece at 45 degrees. We remove burrs from the cutting lines and round the edges.

We place a workpiece of a smaller cross-section inside the larger pipe so that its flat end protrudes somewhat from the outer pipe. On the inner pipe we place marks under the cut and at the level of the edge of the outer workpiece.

We evenly perforate the entire cylindrical surface of a small-diameter pipe between the marks using drilling.

We prepare two conical plugs for a larger diameter pipe and one for a smaller one. We drill holes of a given diameter in them.

We place the smaller plug on the hole of the larger one and secure it with welding. Clean the weld seam.

In a large plug, we install a pipe with a perforated flat end vertically in the center and weld.

We cut a strip of a given width and length from a roll of fine-mesh metal mesh and tightly wrap it around the perforated pipe in several layers. To prevent the mesh from unwinding, we secure it to the pipe with three plastic clamps.

We wrap the mesh at one end with soft wire and secure it tightly with a twist. We wind the wire over the mesh in a spiral and also secure it with a twist at the other end of the pipe.

We place the pipe with the mesh in the large pipe until it stops at the ring element of the conical plug and drill holes in them along the circumference. Using a hand riveter, we connect these parts to each other with rivets.

We tightly pack mineral wool with compaction into the annular gap between the pipes and tightly close the gap with the second element of the conical plug using a hammer. We also drill holes around the circumference and fasten the parts with rivets.

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We remove the protective mesh from the engine and, after removing the old exhaust pipe with gasket, install a new one.We start the engine and, changing the speed, make sure that it is noisy.

We shorten the exhaust pipe and, using sections of pipes and turn signals, create an exhaust system, which we complete by connecting our homemade muffler.

Then we dismantle the exhaust system with muffler from the motorcycle and hermetically weld all the joints. After cleaning the seams, we install the unit in place. We start the engine and make sure that the sound of the running engine, even at maximum speed, has become several times quieter than before.