How to make a muffler on a motorcycle - many owners of motorcycles are set in such a question, especially domestic, who have appearance Future factory silencers leaves much to be desired. The need for the manufacture of a self-made silencer may even have the owners of imported motorcycles, for example, with their tuning (Castomasing). You can of course paying a certain amount of money, buy ready-made silencers from some kind of company, but often they are not suitable for some models of bikes and their attachments have to redo. And they are not enough. In this article, we will look at how to make silencers for a motorcycle with their own hands, with a minimum budget, and that it will be needed for this.
In general, in one article, it is simply not realistic to describe the manufacture of silencers for all types and models of motorcycles, because all the bikes are different, the fastening points of the silencers are also, and the options for the shapes of the silencers and their attachment points, even for one motorcycle model, may be several.
But still describing the manufacture of a silencer of some particular type and shape, this will serve as an example for the manufacture of any other outlet pipes and silencers, because the principle of manufacture is almost the same, with the exception of some trifles (pipe diameters, sizes and fastening points).
Below will be described the manufacture of two different options Silencers, which differ in their inner design. That is, I will describe the manufacture of a conventional silencer with partitions, according to the type of factory. And the manufacture of a direct-flow silencer will also be described, which will add the power of the bike, but also sound louder. And so drove.
Tools and materials for the manufacture of the muffler.
Before starting the manufacture of silencers and their nozzles, you should decide on the material and tool. From the tools you will need a Bulgarian, pipe bender, and it may be necessary if for example you want to connect two pipes into one silencer (however, this can be done with the help of a grinder, but just longer). Well, you will need a familiar turner, to pull the adapters between the outlet nozzles and the jars of silencers.
1 - Case (Bank), 2,3,4,5 - partitions, 6 - plug, 7 - plug screws, 8 - flute holes, 9 - Flute pipe.
Flute options and partitions can be several, but the two simplest and efficient designs that have been worked out for a long time, I have public on the left and below. In the first design, a labyrinth for exhaust gases Create holes (see photo flutes and photo on the left).
And in the second design, the labyrinth creates tubes, welded in partitions. By the way, on many modern motorcycles, a labyrinth from the tubes is used (see photos of the Sportbike silencer above), and such a design is used a long time ago on the motorcycles of the 50s - the photo on the left.
The distance between the partitions should be approximately the same and correspond to the length of the pipe of the can, so before starting to make flute with partitions, you should cut off the jar of this size you like and what suitable for your bike.
If the distance between partitions is equal to the entire length of the jar of the muffler, then this will allow evenly distributed to sound waves.
And so that the flute does not hang inside the jar of the muffler, the extreme pipes of the flute should hoping tightly on the inside of the adapter, where the distance B is indicated in the picture on the left.
Adapters (two for each silencer) should be ordered to roll out of stainless steel, aluminum or titanium, and black steel can be used, but it will have to be used. The drawing is shown in the figure on the left, but the form may not necessarily be on these figures, and somewhat different, such as the front, as well as the rear adapter may have a cone shape. And the rear adapter - the nozzle can be ordered to pull the clock in the form of a rocket nozzle. Or make a nozzle in the form of a multi-venerable machine gun (as in the photo at the beginning of this article), it all depends on the fantasy flight.
But when pulling adapters of any form, it should be noted that the diameter A should be equal to the inner diameter of the pipe of the jar that you will use. And the largest diameter of the cone should be equal to the outer diameter of the cone pipe of the exhaust pipes, but the diameter in should be equal to the inner diameter of the flute tube.
After making adapters, everything is assembled as in the picture on the left. It remains only to consolidate adapters to the jar of the muffler. The front adapter can be connected to the can not clog, that is, with welding or ripples in a circle. But the rear adapter (from which exhaust gases will leave), it is better to fix the can with screws to the case.
To do this, a pair of holes are drilled in the adapter and the internal thread M5 or M6 is cut. The collapsible connection (on the screws) of the adapter and banks will allow, if necessary, remove the rear adapter and remove the flute to clean the nagar. By the way, owners of choppers or old classic motorcycles, you can still produce or order a nozzle on the back adapter, for example, on the photo on the left, which is welded to the rear adapter, or tightly dresses and attached a pair of ripples.
When the silencer is assembled, it remains to be welting with inner Course banks for fastening it to the frame. But it is possible not to weld the ears of attachment to the jar, but drill from the inside of the adapters of the hole for 7 mm, and cut into the inner thread M8. And the bolts (or studs) will be screwed into this thread, for fastening the silencer to the frame. Which option to choose, everyone chooses himself. But both options are much better and more carefully than the factory fastening of the muffler with the help of clamps, which is used on some domestic motorcycles.
Securing the homemade silencer on the frame, now you can measure the roulette, how much should be lengthening the regular exhaust pipe to dock it with a new silencer, well, or make a new nozzle. In the manufacture of nozzles at the factory, there is a thin-walled pipe, and you also advise you to use it (better than stainless steel) to facilitate the weight of the exhaust system.
But the main difficulty in the manufacture of exhaust pipes from a thin-walled pipe is to make a high-quality bending of the pipe under the desired bend radius, without folds and dents. For this purpose, famous customizers use expensive pipe bending with Dorny (more about this reference to the pipe bender above). Beginners of customizers, and most just owners of motorcycles who have decided to improve the appearance of silencers of their bike, such machines are not affordable.
But now you can find on sale ready-made bent pipes or fragments of pipes (approximately as in the photo on the left - they are made of stainless steel and are designed for the rail). For V-shaped motorcycle engines of Harley or Japanese choppers, the fragments of the hound 55 pipes used for silencers of some cars can be approached.
And cutting under different angles, then mixing and welding a bent fragments with each other, you can make nozzles with almost any bizarre bend form. After welding fragments, of course, all welds are polished and then polished, and the outlet looks like a one-piece.
In the manufacture of the exhaust pipe, it should be achieved so that it is at its length reaching the jar of the muffler, and tightly inserted into the opening of the front adapter. By the way on the nozzle and in the adapter hole it is useful to make a small cone (only 0.5 - 1 mm., See the adapter's drawing, the cone is indicated by the arrow) and then the nozzle is very tightly inserted into the muffler adapter. But if you wish, you can still use a special heat-resistant sealant, which is used for mounting graduation system cars.
Of course, what was described above is not the only option of making silencers and their partitions. There are many options, and some even make the silencer system, as the same as a weapon (trunny) silencer - see photo on the left.
Or for example, for caste silencers, many customizers do not use a separate bank and adapters at all, that is, the outlet nozzles themselves are silencers. Only exhaust pipes can be smoothly bend and expanded, and the devastating elements (flute or part of the flute) - if there are, they are simply tightly inserted into the pipe, and they are fixed with some kind of low-speed screw, with the inner (not visible outside) part of the pipe.
And in such silencers, if you establish some partitions, but only in order to remove the high frequencies of sound waves, and the lower spectrum of the exhaust, which gives solidity to the sound, remains. Setting the silencer sound is a whole science, and to achieve the necessary sound, some customizers try several different options for the designs of noise absorbing elements until the desired result is achieved. Some even keep their designs secret.
How to make a silencer for a motorcycle direct-flow.
Many owners, both serial motorcycles and customs, instead of full-time silencers, use a direct-flow silencer, which adds and sound and sound. In addition, the solid sound contributes to the safety of a motorcyclist when driving in traffic jams, and those drivers who do not recognize are more often noticed for what in the rearview mirror machine.
But it is not cheszewo to buy a direct flow for a motorcycle from some kind of authoritative firm. How to make it for cars I have already written (you can read about it), and the device of automotive and motorcycle direct lifts is almost the same, with the exception of their size. Therefore, it makes sense to click on the link and read about the manufacture of forward-point in more detail. But in this article, I will describe some of the manufacturing nuances, as well as to remake the factory silencer in the forward flow.
Redo the factory silencer in the direct-flow is easier, as you can use a regular jar as a case. Especially if on your bike branded regular bank with a logo of some kind of authoritative firm. After a neat alteration, the usual silencer will turn into direct-flow and will also be with the logo of the same company. And if you make a silencer of the forward flow with your own hands using a regular branded bank, you can save a decent amount of money. Since the directing silencers from authoritative firms may not be cheap, approximately 500 - $ 600 (depending on the region and motorcycle model).
The essence of the alteration lies in the neat disassembly of the staff silencer (how to disassemble direct flow or ordinary standard muffler, I described in the repair article on the repair of the direct-flow silencer, the article is located). Especially accustom to disassemble silencers with a carboxyment can (carbonistic), as the carbon exposed to temperature effects becomes even more fragile. With steel or stainless (titanium) banks, work is much easier.
So, disassembled a regular jar, take out all the insides (flute with partitions) and instead of them should be made (better from the stainless steel) tube with a plurality of small holes. The diameter of the tube is about the same as the diameter of the outlet nozzles of your bike (30 - 50 mm). And the length of the pipe should be such that enough from the front adapter, to the back cover, that is, almost the same as the length of the standard bank.
In the tube weathelate a plurality of holes with a diameter of 3- 5 mm (see photo on the left or above - all conditional sizes and can be changed). Next, the tube is welded or fastened on the neck to the front adapter of the standard silencer, and the back of the tube will have to hoped tightly when assembling on the internal tubular protrusion of the back cover - adapter (that is, the same as the flute of a conventional silencer is worn, to the protrusion of the rear adapter - cm . Drawing of a collected conventional silencer, slightly higher in the text).
After the perforated tube is welded to the front adapter, it is tight (in several layers) is winding with mineral or basalt cotton. 
The number of layers and the winding thickness should be such that the regular bank is tightly running on the winding, when assembling the muffler. After putting on the banks and docking it with the front adapter (with the help of ripples), it will stay to put on the jar and the perforated tube the back cover and copold everything with ripples or screws (see photo on the left).
When docking the perforated tube and protrusion in the back cover of the silencer, you can use the thermoegertic, for the seal, if for example the perforated tube sits onto the protrusion of the back cover is loosely (with a gap).
That's it seems to be all. I hope this article will somehow help novice motorcyclists or customizers, answer the question how to make a muffler for a motorcycle and apply these tips in practice, success to everyone.
What is the silencer and why is it designed? The goal is to familiarize you not only with how to construct your own self-made silencer for a scooter, but also with what the purpose of this important node.
Two-stroke and four-stroke scooter
Scooter, as you know, can be with a two-stroke or four-stroke engine. The principle of operation of the entire exhaust system in the analogs is highly radically.
The silencer on a four-stroke scooter for a relatively smaller time displays gases, making it with minimal noise. In addition, it will be quite simple to spend tuning of the muffler in this case. On the other hand, in both cases, conducting tuning, it will be necessary to change the pipes.
For the silencer of the two-stroke scooter, select the components that give the ability to spend tuning, it will be much more complicated. The regular muffler itself for such scooters is more complicated in production and configuration.
The exhaust system of the two-stroke scooter works as follows. In the process of cleaning spent gases, part of the power returns to the engine. It happens on certain revs and if you can realize this whole process, having tuning, the scooter will not know.
You can install a qualitative and proper resonator on a two-stroke scooter. This will give a tangible increase in dynamics to a quarter. But in this case, the professional settings of the entire nutrition system will be relevant.
What do you need high-quality silencers
As is known, a certain amount of fuel combustion products is assembled in the moped engine cylinders. They must be thrown out and in this case it is the muffler in response for it. In other words, this node seems to smooth ripples, inevitable when emissions of combustion products at high speed.
The design of the silencer, used not only on scooters and mopeds, but also on motorcycles and cars, implies a special system of the graduation path, which may be different, depending on which result wishes to receive the owner vehicle. For example, if the desires to improve the gas output system are associated with an increase in the power of the scooter, a special type of silencer is needed - direct-flowing.
River type silencer
The installation of this type of silencer will entail not only an increase in dynamic power, but will significantly increase the noise issued upon gases. On the one hand, it is good, because it is possible to attract the attention of other drivers, thereby increasing passive security. As you know, often drivers large cars They complain that they do not notice motorcyclists, well, and mopeds and scooters are suppressed.
Make such a silencer from scratch or the method implying tuning is easy, but it is necessary to study many technical aspects.
Features of the direct-flow muffler
Features of the forward-point in the following: Exhaust gases are thrown out of the engine at once, cylinders power aggregate We manage to fill the fuel mixture in optimal quantities.
I would like to remind all readers that at the moments of the intake and release valves of the engine have the properties to open and close. There is a vacuum between these stages, which allows you to clear the cylinders from the gases produced. As a result, free space is exempt where fuel mixture. It is easy to guess that the faster the cylinders will be released from developing, the faster it will be filled.
Thus, if you can easily provide a faster gas output from the system, the productivity will increase and due to this, the power of the scooter or moped.
Cleaning the muffler
Before starting to change something in the exhaust system, I would like to give one advice. The purity of the muffler directly affects the power of the scooter. If it were possible to see the work on the silencer, the owner of the scooter would be very surprised. After a certain mileage, the dynamics of the scooter decreases, and the owners begin to seek the reasons for this, finding them in a complete alteration of a regular silencer or its replacement.
The cause of power loss, meanwhile, can be hidden in the state of the engine itself. It will help identify a specialist to which you stand before tuning. But most frequent cause The dynamics loss becomes a soot that scores the muffler. Cleaning B. this case It is recommended to spend three ways.
First method: mechanical
It implies cleaning in the cut of the muffler (it is done by the grinder). The inside of the muffler from soot is sulfted with wire or cable. The location in the section closes with welding.
Second way: chemical
He implies the bay of water with some cleaner in the muffler. For example, the caustic soda is suitable for this purpose. With such a cleaning there is an advantage: the appearance of the silencer in no way will suffer.
Third way: thermal processing
The muffler is heated either on the scooter by a soldering lamp, or dismantled in the furnace or on the grill. It will be necessary only after cooling to repaint the silencer.
Alteration of the muffler
As a rule, many craftsmen are not just collecting the muffler, but rewor the regular one. This makes it possible to spend less time and get a more acceptable option.
Tools and materials
Before start tuning, you need to prepare required tools. In this case, the following components will be necessary:
- Welding machine, preferably with different modes of operation;
- Appropriate size and diameter pipe;
- Bulgarian;
- Brushes for washing dishes metallic in the amount of several pieces.
We start tuning
We dismantle the silencer for the beginning. Then take the grinder and cut out a piece of metal from above the muffler. In such a section with the silencer will be much easier to work. Practically should be completely cut up the top. After that you need to clean everything inner space The silencer, carrying out disassembly in the context of the elements.
It's time for working with a pipe cut, which we have prepared. Taking advantage of a powerful drill or welding, we spend a lot of holes in the pipe. We place the pipe in the context of the full silencer. We select a pipe of this diameter in advance so that it fit inside the regular one. It is desirable that the pipe is without any obvious flaws and perfectly smooth.
The space in the context, which will remain between the two pipes, you need to score with metal brushes or similar materials. Brew the top of the pipe, as it was. Mount the back all the design elements that were dismantled during the process.
As a result, which gave tuning, we will have a shipping silencer, providing the desired result. The massive and juicy roar of the engine, as well as the increase in the power of the moped will be evidence that everything went successfully.
We make a straight-flow silencer from scratch
You can make such a silencer from zero. It will be a completely new option made of several components. The complexity of this operation called tuning from scratch is to search for the scheme of the exhaust system of a certain moped.
Tools and materials
In this case, again, it is necessary to prepare the necessary tools and material.
- Purchase in the store or find two pipes, with a diameter of 33 mm;
- Buy plexiglas;
- Bolts M8 and M3;
- We prepare glue and nails;
- Welding machine;
- Nadfili;
- Metal hacksaw.
Start assembly
First of all, it is necessary to cut off from one of the pipes 18 cm. The location in the context is recommended to carefully treat the supfyl. From the second pipe, cut a circle, with a diameter of 1.5 cm. Processing the above-described method. We glue in the context of the first pipe, cut circle. Cut off another piece of the pipe, with a length of 18 cm. We do a lot of holes in it. This can be done with a sharp nail.
Connect all parts using a welding machine. Mineral wool stuff the cavity formed in the junction of two pieces of the pipe. Watch the finished product with a special fire-resistant material. Homemade muffler is ready. To establish it, it will be necessary to make an element to the attachment of the scooter housing.
Make the element of the fastening of the muffler
From the plexiglass, which is indispensable in this case in mind its strength and light dyeing, cut out a special kind of ring, the edges of which can be dispersed outward 180 degrees. The resulting circles with sneakers are attached to the mop, using the bolts. The silencer is polishing with the emery paper. Connection sites Self-timers with a moped body for loyalty will need to lubricate.
If a homemade manufacture Causes certain difficulties, you can find a lot of models of silencers already in the finished form. They are usually inexpensive. On the other hand, only homemade version Can give the perfectly expected option.
Instructions, how to independently give a new and beautiful view of the old silencer, and at the same time make it more quiet.
Item 1. To work, we need.
Materials:
Cut thin stainless steel, 0.4-1 mm thick.
Segment of a tissue, rolled heat-resistant noise absorber, a thickness of ~ 5 mm.
Instruments:
Semi-automatic welding.
Bulgarian with a thin disc 1 mm.
Clause 2. Causes.
Over time, even the most famous manufacturers of motorcycles, as in this case, Honda, there is a complete blockage of the silencer with exhaust sediments, after which the motor will not start and exit here only two, buy a new Chinese silencer or disassembling and cleaning the old.
But since in the Chinese muffler there is a completely lacking system of the reverse wave resonance, that is, it is just an empty bank, it is also very thin, and as a result for two-stroke motorThis is a loss of power up to 50% and as a result of the scooter completely stops riding!
During the disassembly of the silencer, it is necessary to forced to remove the inner noise absorber of the fiberglass housing, after which the sound of the working scooter becomes more loud and nasty (ringing), that is, rings and resonates the case of the case of the case, and the appearance is no longer so neat as before.
Therefore, independent installation An additional decorative case with an additional noise absorber will be very by the way.
Item 3. Production and installation.
We unscrew and remove the muffler.
We measure the length of the circle of the jar of the muffler and the length between the welding seams.
We add 2-3 cm for the resulting circle dimensions. For the adolescence, and 2 cm for bends to the width.
Cut the calculated rectangle from fine stainless steel.
On both sides of the wide part of 5 -6 mm bend.
Polishing the surface of the paste of Goe.
We make a thin disk with a step with a pitch of 5 mm.
We remove sharp edges and burstles.
According to the resulting dimensions, cut the cut cutlery (for example, asbestos are weave, fiberglass or other), so that it is tightly included in the bend.
Wrap around the jar of the muffler, so that the joke was on the back side.
For the convenience of welding, fasten the clamps or other fasteners (for example; rubber rings).
We produce spot welding.
Hello everyone!
A small topic on the construction of the silencer "directly". For example, it was based on the moped, but it's no different from the car. It is not possible to give everything in the "knee" in the shed, you just need to order a familiar drunk turque to the details and find a piece of stainless steel. Balango I have a native factory at hand, where I have round-the-clock access to metals various brands and machinery . A smooth pipe and weld with point welding.
Further turning (I sharpened myself) we drew 2 washers for the desired diameter.
And for what the film on the pipe? For the inscriptions of course!) For myself, I chched the Poultry Ponte inscription Zide Sport.
If there are no films, you can stick a wide isolent. You first print on the printer, then we glue to the pipe and cut the scalple or special. A knife. When you carefully removes the elements and voila we needed, the stencil is ready. Krasim. 
Rejoice in the resulting inscription 
Next, you need to make a grid or grid with cells with a finger pipe of the desired diameter inside the muffler. 
All this insert so that the holes coincided with this pipe, stitching tightly wool type URSA or KNAUF (these are building insulation) wool so withstands a large enough temperature and does not fly out of the pipe due to the mesh inside. CEREDUNY remains completely free on shining there with a flashlight we will see the nozzle even)
That's all. This was all done for free. 
Each self-respecting motorcyclist spends a mass of time and effort on improving its own apparatus. Improving engine capabilities, improving tank characteristics, attention in the end switches to the exhaust system. A new guide on a motorcycle, with your own hands set, will delight the eye and drive a driver. Modernized exhaust system It looks more stylish on the motorcycle, aesthetic, and a loud sound makes a bike noticeable on the road and helps to avoid unpleasant situations.
What is a forward flow?
The direct flow is called the design for moving liquids and gases in a single direction. From the factory, the motorcycle comes with a standardized exhaust system, but subsequently customization of the bike and increase its capacity of the original configuration is not enough - the amount of exhaust gases increases. Specialists establish a forward-point system, visually and technically engraving your motorcycle (power will increase by 3 - 5 horse power), however, more pleasant to do it with your own hands. It does not require high time costs, the materials are quite accessible, it remains to be armed with information.
How to make a muffler on a motorcycle?
· Unscrew the fastening bolts and remove the old factory silencer.
· Pull the standard insides - tubes and other luxury.
· Get \u200b\u200bthe thin-walled tube or make yourself from the girlfriend garage materials. Stainless steel or aluminum without defects are optimal option. The grooves, chips and holes will return unpleasant metallized noise direct flow, and the wrong dimensions of the tube will hamper the gas exhaust. Be careful, creating a muffler on a motorcycle with your own hands: maintenance requirements should not be violated.
· The outer shell of the muffler and the thin inner tube differ significantly in the volume, the lumen between them is recommended to tightly score with glass - this will help reduce the noise. Risk of ignition The glass gambles are minimized if the tube is copied with a fire-resistant substance or asbestos.
· With the help of fasteners, we add the silencer back to the motorcycle, cover the outlet of the lid and check the result of your handmade. When the bike becomes, you must hear a light bass tone. If you want more expressive effects in the sound of the forward-time, there is a different way to create a silencer, about which we will also tell me further.
How to create a sonorous direct flow on a motorcycle with your own hands?
· There are a large number of directions: Some enhance power, others improve the sound, the third category of direct docks gives a double result.
· The essence of the work of high-quality forward-point is to control gases and liquids in a motor-heat exchanger, directing the biased wall of the substance in a single direction.
· Having conceived your own project of direct-point, be sure to read the workshops laid out on the network. If you have experience and engineering thinking, you can experiment and invent new types of direct lifts.
· Making a unique silencer on a motorcycle with your own hands will help the welding machine and Bulgarian. To do this, we buy a sheet stainless steel, we turn it into the pipe, bonding individual elements of arc-argon welding. The inner tube is also made, only in a smaller diameter, and a plurality of fine holes are drilled in the steel sheet. At the final stage, end plugs are attached.
· The further process resembles the change of the original silencer homemade. Stuffed glass wool, tighten asbestos. Fill the space between the shell and the tube is needed denser, then the vibration and noise will be less during the ride.
· Some experts redirect car silencers on motorcycle, how do they do and what does it give? The only difference consists in excellent motorcycle and auto-mounts, which can be adjusted by the welding machine. The seams are embarrassed by chrome paint. At the output we get a stylish velvet sound of forward-point and increased power indicators. Pleasant bonus - satisfaction from work and tangible savings.
Information on how to make a muffler on a motorcycle is quite popular not only in tuning professionals and craftsmen with golden hands. We believe that every engine must have these knowledge, given the simplicity of the workflow and the availability of materials.
