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

Two stroke and four stroke scooter

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

The muffler on a four-stroke scooter removes gases in a relatively shorter time, doing this 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 the muffler of a two-stroke scooter, selecting components that make it possible to carry out tuning will be much more difficult. The standard muffler itself for such scooters is more difficult to manufacture and configure.

The exhaust system of a two-stroke scooter works as follows. During the process of cleaning exhaust gases, part of the power is returned to the engine. This happens at certain speeds and if you manage to implement this whole process by tuning, the scooter will be unrecognizable.

You can install a high-quality and correctly tuned resonator on a two-stroke scooter. This will give a noticeable increase in dynamics up to a quarter. But in this case, it will be important to carry out professional settings of the entire power system.

Why do you need quality mufflers?

As you know, a certain amount of fuel combustion products accumulates in the cylinders of a moped engine. They must be thrown out and in this case it is the muffler that is responsible for this. In other words, this unit seems to smooth out the pulsations that are inevitable when combustion products are released at high speed.

The very design of the muffler, 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 wants to get vehicle. For example, if the desire to improve the gas exhaust system is related to increasing the power of the scooter, a special type of muffler is required - a direct-flow muffler.

Direct flow type muffler

Installing this type of muffler will not only increase dynamic power, but will also significantly increase the noise emitted when gases escape. 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 often large cars they complain that they don’t notice motorcyclists, and mopeds and scooters even more so.

Making such a muffler from scratch or using a method that involves tuning is not difficult, but many technical aspects need to be studied.

Features of a direct-flow muffler

The features of direct flow are as follows: exhaust gases are ejected outside the engine immediately, the cylinders power unit have time to fill with the fuel mixture in the optimal quantity.

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 the cylinders to be cleared of exhaust gases. As a result, free space is freed up, where it is supplied fuel mixture. It is easy to guess that the faster the cylinders are released from exhaustion, the faster they will be filled.

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

Cleaning the muffler

Before you start changing 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 were possible to see the exhaust in a cross-section of the muffler, the owner of the scooter would be very surprised. After a certain mileage, the scooter's dynamics decrease, and owners begin to look for the reasons for this, finding them in a complete rework of the standard muffler or its replacement.

The reason for the loss of power, meanwhile, may be hidden in the condition of the engine itself. This will help determine the specialist you should contact before tuning. But most common cause Loss of dynamics becomes soot, which clogs the muffler. In this case, it is recommended to carry out cleaning in three ways.

First method: mechanical

It involves cleaning the muffler section (it is done with a grinder). The inside of the muffler is cleaned of soot using a wire or cable. The section in the section is closed by welding.

Second method: chemical

It involves pouring water with some kind of cleaner into the muffler. For example, caustic soda is suitable for this purpose. There are advantages to this type of cleaning: appearance the muffler will not be damaged in any way.

Third method: heat treatment

The muffler is heated either on the scooter with a blowtorch, or dismantled in an oven or on a grill. It will be necessary to repaint the muffler only after it has cooled.

Muffler conversion

As a rule, many craftsmen not only assemble a muffler, but remake a standard 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 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. Several metal brushes for washing dishes.

Let's start tuning

First we dismantle the muffler. Then we take a grinder and cut out a piece of metal on top of the muffler. With this cut it will be much easier to work with the muffler. You should almost completely cut out the top part. After that you need to clear everything inner space muffler, dismantling the elements located in the section.

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 section of the standard muffler. We select in advance a pipe of such diameter that it fits inside the standard one. It is desirable that the pipe be without any obvious flaws and perfectly straight.

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

As a result of the tuning, we will get a forward flow muffler that provides the desired result. The massive and rich roar of the engine, as well as the increase in power of the moped, will be evidence that everything was successful.

Making a direct-flow muffler from scratch

You can make such a muffler from scratch. It will be completely new option made from several components. The difficulty of this operation, called tuning from scratch, is finding a circuit exhaust system a certain moped.

Tools and materials

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

1. Purchase in a store or find two pipes with a diameter of 33 mm;
2. Buy plexiglass;
3. Bolts M8 and M3;
4. Prepare glue and nails;
5. Welding machine;
6. Needles;
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 needle file. From the second pipe we cut a circle with a diameter of 1.5 cm. We process it using the method described above. Glue the cut out circle in the section 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 scooter body mount.

Making a muffler mounting element

From plexiglass, which is indispensable in this matter due to its strength and easy paintability, we cut out a special type of ring, the edges of which can be bent outward by 180 degrees. We attach the resulting circles with serifs to the moped using the required bolts. We polish the muffler using sandpaper. To be sure, the joints between the homemade product and the moped body will need to be lubricated.

If homemade production causes certain difficulties, you can find a lot of models of mufflers already in finished form. They are usually inexpensive. On the other hand, only homemade version is able to give the ideally expected option.

One of the most important disadvantages of any motorcycle is the unpleasant sound produced by a high-speed engine - its tonality has a depressing effect on the human nervous system. At the same time, the volume of such sounds leaves no doubt that they will be heard by people within a radius of several city blocks. That is why engineers created a special muffler for a motorcycle, which not only reduces the volume of unpleasant sounds, but also seriously changes their tonality. However, any obstacle on the way exhaust gases forces you to reduce engine power for the sake of its safety. Therefore, many are interested in how to make two-wheeled vehicles more powerful without sacrificing their health and the comfort of those around them.

High-quality forward flow

Despite the apparent complexity of such an operation, you can make a direct-flow muffler for a motorcycle yourself, saving up to $1000 on the purchase of a product from a famous brand. First of all, you should decide on the type of materials you will use in your work. Experts give the following recommendations:

• The best option would be titanium, since it has very high strength with minimal weight. However, bending titanium sheet to produce a muffler will be very difficult, as will finding welding equipment. You don't even have to mention the incredible high cost titanium;
• Aluminum is excellent for muffler production for the reasons described above. However, when using it, it will be problematic to connect the device to the motorcycle engine;
• Stainless steel has a large mass, but is durable and quite easy to bend. To weld a motorcycle component from this material, you will need specialized equipment;
• Ferrous metal is heavy, has low reliability and requires repeated processing. However, it is recommended for use by beginners due to the ease of bending and welding.

The thickness of the metal should be approximately 0.8-1.5 mm so that it can easily bend and weld without burning. Once you've selected the metal that best suits your muffler, spend some time researching the required equipment to cut and weld it.

Now it’s time to make muffler patterns for a motorcycle. The first thing to make is the resonator cone, which connects the device you are making to the motor of the two-wheeler. You can also make it yourself - to create the correct pattern, you need to remember that the planar projection of the cone is a sector of a circle. Next, pipes are taken that correspond to the diameter exhaust system- there should be three of them. Remember that it is better to take the pipes ready-made, although if desired or if there are no suitable materials, you can weld them yourself.

The first pipe will be approximately 50 mm long (more if necessary) - it will connect the engine to the new muffler. The second will serve as an outlet - it needs to be given a similar length. The third will go inside the muffler housing and will serve to reduce the intensity of sounds. To get a quiet enough muffler, you need to make the last pipe long enough. However, it is worth understanding that increasing it will lead to a lengthening of the motorcycle muffler housing.

All that remains is to cut out the body itself—whether it will be cylindrical or flattened depends only on your desire. The minimum diameter of the case is 100 mm, but if possible it should be 150-170 mm. The sides of the body are made of similar sheet metal, after which holes for pipes are made in them. The first and second pipes described above are processed, after which they should form a flange that allows them to be firmly secured inside the muffler. In the third pipe you need to drill many holes - the best option There will be holes with a diameter of 1 mm in increments of 10-15 mm, then insert it inside the body and securely fasten it between the first and second.

The last step in assembling a motorcycle muffler is to fill it with a non-flammable material that dissipates sound - fiberglass is suitable for this. It needs to be laid as tightly as possible to achieve maximum muting. unpleasant sound. Now you can finally weld the motorcycle muffler and... If you are doing such work for the first time, it is better to first try to make all the patterns from thick cardboard and try on a similar homemade muffler for your motorcycle. If you make a mistake, you will be able to understand exactly what the mistake is and correct it without wasting expensive metal.

Alternative options

If you're wondering how to make your muffler quieter without wasting precious horsepower, you can use a scheme that has been used in Chinese motorcycles for quite a long time. However, it is worth remembering that similar option Suitable only for the production of mufflers for low-power motorcycles, whose performance does not exceed 40 hp. With. A pipe is inserted into the muffler body two-thirds of its length, the last 10 centimeters of which are covered with small holes according to the scheme described above. Having installed the inlet pipe, we are engaged in the outlet, which will be a pipe of a slightly larger diameter, inserted from the opposite side by two-thirds. It also remains to drill holes in 10 centimeters located closest to - such a muffler will represent a compromise between forward flow and the factory product.

If you know the structure of a motorcycle muffler, you can probably make a forward flow from an ordinary part. After opening the housing, you will see tubes that pass through special chambers, first to the end of the muffler, and then back and again to the exhaust pipe. These, as well as the motorcycle's catalytic converter, will need to be removed to achieve the desired effect. The perforated tube mentioned in the previous diagrams is inserted inside and wrapped with fiberglass. Of course, you can buy a special synthetic material used in the packing of original mufflers, but it will obviously cost more.

If you already know how to make a motorcycle muffler that perfectly suits your requirements, don't forget about fine-tuning the exhaust - for this you need to select optimal diameter and the position of the pipes, as well as the density of the holes. Achieve perfect result without the use of a special stand it is almost impossible, so you will have to be content with approximate parameters obtained experimentally. In addition, after installing a different muffler, the motorcycle engine should be retuned. Modern injection engines installation required new firmware, but carburetor motorcycles get by with simple adjustments fuel system. Not everyone can do this kind of work, so it is quite possible that you will have to go to a specialized service center.

Independent work

Making a motorcycle muffler can be quite simple, but will it fully meet the requirements for it? Get ready for the fact that the first product you make with your own hands will require certain modifications and many hours of adjustments. However, practice shows that the second or third time it is possible to make a muffler for a motorcycle that initially meets all the required parameters. Sometimes it happens that to make required muffler for a motorcycle is not possible at all - the reason for this may be a lack of experience or certain design features technology. In this case, it is better to buy a finished product from a well-known manufacturer or order the production of a direct flow from a real professional.

It is difficult to imagine a sports or tuning city car without a direct-flow muffler. The noble roar of the engine pleases the sensitive ears of the owner, thrills girls, and arouses the envy and admiration of friends. However, neighbors do not always like this, and the traffic police prefers a quiet direct 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 muffled

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

Having decided to muffle the forward flow with your own hands, you need to clearly understand the principles of operation of the agreed release, and determine the purpose of the car tuning performed. Improvement in dynamic characteristics occurs only through the installation of a new “spider” - the exhaust manifold. The remaining components of the exhaust system simply should not create resistance to gases and adversely affect the result.

At correct setting, resonant exhaust gives an increase in torque by 3–9% 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 direct-flow muffler on regular stock cars is only needed as a decorative option for a pleasant exhaust timbre. Main criterion the quality of direct flow operation on a production machine is the euphony and velvety noise of the engine, and not an increase in power. The car will scream louder or quieter - at high speeds and dynamic characteristics it will not be reflected. In this case, when there is an urgent need to stop the forward flow, you can do this without thinking about the consequences.

What is a flute in a direct-flow muffler, and what is its effect?

To make the forward flow quieter and get “passing” decibels at the output, a simple design is used, which motorists call a flute. This is a piece of perforated tube with a length of 180–250 mm and a diameter of slightly more than 1/3 of the exhaust, with a welded plug washer 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 the flute for direct flow is that when the cross-section of the exhaust channel changes and exhaust gases exit through the perforations, the following occurs:

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

The correct name of this flute is silencer (from the English silencer - muffler), and it is included in the kit expensive systems exhausts that are sold on the Internet. 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.

DIY flute for direct flow

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

To work, you will need a 20 mm steel (preferably stainless) pipe and a piece of sheet metal 0.8–1.2 mm thick. It is advisable to cook using arc welding, following the rules for working with stainless steel. A pre-bent steel sheet plug with holes for fastening is welded to the pipe. You can screw it with three M8 bolts, but for installation in a few minutes, one threaded connection is enough.

During manufacturing, you should try to carefully measure the internal diameter of the muffler at the air end so that the plug fits in loosely, but without a gap. Then, when heading out to 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 obstacle in exhaust pipe, including the silencer, inevitably reduces engine power. It’s definitely not possible to make it quieter and muffle it without loss.

To make a quiet direct-flow muffler, but not lose the additional power that modernization of the exhaust tract gives, use a direct-flow muffler with a damper. This exhaust design has been known for a long time and is found on many BMW models (usually with manual transmission).

When the engine is running at low settings, when the advantage of the coordinated exhaust is not taken advantage of, the exhaust gases exit through a conventional muffler, and the direct-flow muffler is closed with a damper. At optimal speeds, the damper opens the outlet into forward flow, and the motor produces 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 sounds almost no different from a stock one, and on the highway it not only sounds like a tuner, but has a real increase in power. It's not cheap - for full automatic, complete with a titanium “spider”, the price often exceeds a couple of thousand dollars.

Similar in capabilities, but not very famous analogues cost moderately, but choose suitable option It’s better to work with a specialist - the success of such an upgrade may require the knowledge of a motor engineer.

A budget option for direct flow with a damper can also be welded yourself from scrap materials. The top part from an old carburetor is suitable for the damper, if you remove the cable idle move to the salon. Making such a design with your own hands will take much more effort and time than for a homemade flute, and the result of the installation cannot be predicted in advance. It's not difficult to mute the sound, but to maintain power, even if you're lucky, you'll have to tinker with the settings.

Conclusion

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

Hi all!
A small topic on building a muffler “directly”. The example is based on a moped, but it is no different from a car. You can really do everything on your “knee” with a mallet in the barn, you just need to order a couple of parts from a drunk turner you know and find a piece of stainless steel. Fortunately, I have my own factory at hand, where I have round-the-clock access to metals different brand and machines. First, we measure what size the can will be. We multiply the diameter by 3.14 and get the length of the circle in expanded form accordingly. The diameter of mine seems to be 96 mm and the height of the can is 400 mm. It is better to take stainless steel in film, for which you will understand, but it will work without film .We make a straight pipe and weld it with spot welding.

Next, the turner (I sharpened it myself) turned out 2 washers for us to the required diameter.

But what is the film on the pipe for? For inscriptions, of course!) For myself, I made the Pasan pontoon inscription ZiD Sport.

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




We are glad to receive the inscription


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


We insert all this so that the holes coincide with this pipe, we stuff the edges tightly with wool like Ursa or Knauf (these are construction insulation materials). Such wool can withstand quite high temperatures and does not fly out of the pipe due to the mesh inside. The middle remains completely free and if If you shine a flashlight there, we’ll even see the pipe)
That's all. It all cost me free.