after watching a couple of videos about making exhaust silencers like this one
or this one
I thought I'd have a go at making my own for my 1.0L vw polo. I know very little about the acoustics for exhaust design, but thought that having chambers in the back box and the exhaust gases having to go round the silencer a couple of times would help as well as the exhaust pipe being the standard 1.5" diameter should help keep it quiet, but only time will tell.
I also wanted to make it from stainless steel and tig weld it, so I thought that if I used lap joints I could autogenous weld the joints to make it easier with having to use filler rod. I also thought about making it without back purging it (to prevent sugaring) by using either backing blocks or SIF tig purging flux, but at nearly £50 for a jar may seem expensive but a little goes a long way, so may work out cheaper than purging over time, and I plan on using this for making the pie cut bends for the pipework.
to begin with I thought I'd make the end plates for the silencers, and to the edges of the holes and outside would need forming, so thought I'd make a backing plate to do this, using 5mm thick mild steel with a plywood backing, for the back box the holes were co-ordinate drilled
and then bored out
for the front silencer they were turned on my lathe
the end plates then had the holes drilled in them
the flanges on the holes were done by hammering a tapered wedge though the end plate and using the steel backing plate. the plywood top plate as to stop the stainless sheet sheet from buckling.
the outside flange was hammered over a 5mm steel former, (with plywood backing)
and the completed end plates for the front silencer, and plates that are inside the back box (I forgot to add the end plates for that to the pile)
or this one
I thought I'd have a go at making my own for my 1.0L vw polo. I know very little about the acoustics for exhaust design, but thought that having chambers in the back box and the exhaust gases having to go round the silencer a couple of times would help as well as the exhaust pipe being the standard 1.5" diameter should help keep it quiet, but only time will tell.
I also wanted to make it from stainless steel and tig weld it, so I thought that if I used lap joints I could autogenous weld the joints to make it easier with having to use filler rod. I also thought about making it without back purging it (to prevent sugaring) by using either backing blocks or SIF tig purging flux, but at nearly £50 for a jar may seem expensive but a little goes a long way, so may work out cheaper than purging over time, and I plan on using this for making the pie cut bends for the pipework.
Tig Purging Flux SIF 500g Tub
A flux used in TIG applications to shield the rear of a weld joint from oxygen contamination, dissipate heat and oxides during welding and prevent re-oxidation.
www.millenniumsuppliesshop.co.uk
to begin with I thought I'd make the end plates for the silencers, and to the edges of the holes and outside would need forming, so thought I'd make a backing plate to do this, using 5mm thick mild steel with a plywood backing, for the back box the holes were co-ordinate drilled
and then bored out
for the front silencer they were turned on my lathe
the end plates then had the holes drilled in them
the flanges on the holes were done by hammering a tapered wedge though the end plate and using the steel backing plate. the plywood top plate as to stop the stainless sheet sheet from buckling.
the outside flange was hammered over a 5mm steel former, (with plywood backing)
and the completed end plates for the front silencer, and plates that are inside the back box (I forgot to add the end plates for that to the pile)