4 Stroke mufflers

[sudman]

Ok I want to build a muffller to suit my XL350, I have made the header pipe 1 3/4" now what's the best way to go with the muffler, any ideas?

Thanks

[oldfart]

Sudman , Think I posted what you are looking for last year
              Explained what I had used and how I went about it, I'm not the worlds fastest key board banger.    If you get stuck I'll repost it 
 
             
             

[sudman]

Thanks any idea what the thread was called

[oldfart]

Just finished a cuppa so I should be good for 1/2 hour 
OD of large pipe is 76 mm  -   taper piece is 76mm X 50mm  - blank 76mm - small pipes 14mm Id

                                         

[oldfart]

Piece with holes drilled in , was re-drilled 6mm and more of .
I trimmed end blank so as to have 5 mm when butted to 76 mm round tube which gave me a nice area to weld  .( not yet )
Then drill a 50mm hole and inserted the 50mm small section with folded edges and welded it to cap ( 50mm piece inside ).....cleaned up weld ...... then welded it to 76mm tube

[oldfart]

Bunning has this ( 14 mm ID tube )  cut 6 pieces 50mm long and zip tie them together which will hold shape while you tack weld one end = 50mm OD
This is then welded to 76mm x 50mm  concentric reducer - baffle is then welded to 14mm sections
which is then trimmed so it fits inside 50mm end blank ( supported )
I have done it this way so as it can be repacked at any time , and internal baffle is supported at opposite end
             (  Pause  refill )

[oldfart]

I have my muffler welded directly to tail section ( for looks ) with baffle being removable with a join mid section for ease of removal

[Nathan S]

Best 4-stroke muffler has a straight-through baffle with an ID of 8~9mm.

Anything else allows them to sound like a f$%king 4-stroke, and should be avoided at all costs.

[211kawasaki]

where are you Shane? 

[mick25]

What about a gmc look a like that he makes for the HL500 it has a internal baffle, so there is no big muffler hanging of the back,or i have seen a two stroke muffler used on a xl350 it looked fine but it wasnt the org sweeper pipe,I have seen a few TT500s with big late models mufflers and they look out of place

[MX?]

What about the good old Supertrapp?
Ebay Item #120485164923 Needs a coat of black though 

[sudman]

Thanks Oldfart I have made a start now, 1 3/4 header pipe stepping up to a mid section 2" power bomb then 1 7/8 into a 300mm long alloy can, as pre your design.
I will post the pictures when all done

[bazza]

supertrapp works with XL but use a lot of discs, Hey old fart are you going PC over there in Auz?? What is packing/ baffeling??  Let it roar

[oldfart]

Had same system  tested at Cd5 with out packing and failed big time 

[sudman]

 :DTwo nights in the shed & it's all done

http://s865.photobucket.com/albums/ab217/sudmanvmx/?action=view&current=camerapics013.jpg