Thread: Project $ 3 K Is Underway

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Then I had to punch some holes into the tubes because that is the way the ones were on that website. They had a bunch of little holes shaped like "scoops" throughout the tube, I guess to break up the sound waves or something. Since I don't have a degree in muffler science, I did the next best thing...........I stole their design. First I drilled a bunch of holes and intended on using my air chisel with the pointy attachment on it, but Dan had already gotten to it and welded some attachment on it for something he was doing. So I just hammered a punch into each hole and shaped it like a little forward facing air scoop.

Then I welded the tube into the flange from the backside so no weld would show, and bolted it on the headers.

I couldn't wait to fire up the car to see if it was quieter, and I have to say it is only marginally so. But this is my starting point, and I plan to add some diffuser rings and some stainless steel scrubby pads inside to see what that does. Maybe when I get the car out in the sunshine it will be acceptable as is, but inside the shop it is still pretty loud.

Now I just have to temporarily paint the flanges with header paint, then after Daytona I will get them Jet Hot coated like the headers. Another advantage is that I think the hot exhaust gasses will now blow by my body rather than scorching it like the open headers might have done. If they are still too close I will add turnouts.

Don

Don, can you put a v shaped piece in the end of the pipe to disfuse the sound, the end going into the header. That might force more back around to your holes.
Brad

What do you think it should look like Brad? How big, etc.


Don

Just enough to block about a third of the pipe, a reverse v pointing into the pipe. The wide end towards the engine.
Brad

you will need more baffle surface and you should wrap the core with glass or S steel wool you do not want to bottle neck it and have way to much back pressure your header will glow and if you get all to work it is still going to be very loud it takes a lot to lower db

Hey Don,Why can't you just buy a cheap cherry bomb,cut away the outer case,weld on your outer flange? I think if you leave enough metal on the end that goes up into the megaphone to make somewhat of a seal,the meg itself becomes the outer shell,and therefore should work the same,right? Hank

Don, do a search on eBay for "Harley baffle" or "harley mufflers" you will see tons of products or get some ideas. for example:
http://cgi.ebay.com/ebaymotors/Steel...WDVWQQtcZphoto

Thanks guys, those are all really good suggestions. For now I am just going to let it go the way it is and once I get it outside and hear how loud it really is I can make a better determination of if and what I need to do to quiet it down more. I am afraid to do too much because it might heat up my headers too much and fry the Jet Hot coating. I already see some spots where it looks like the headers are getting a little more dull than the rest of the finish, nothing serious just a little.

A couple of nights ago I had a Ft Myers Police Officer come to my shop because he bought a small mig I sold on Ebay. While he was there I started the T and he said it sounded fine to him. Of course, he later went on to tell me he has a 500+ cubic inch Dodge Dart that he runs in true street, and also drives on the street occasionally. So maybe he isn't the best judge of the legality of this setup.

Oh, my stainless steel brake lines showed up yesterday from Inline Tube, and of course the box got crumpled by FedEx. They are sending me three replacements on Monday for the ones that got it the worst. Last night Dan and I worked on it a little and got some of the lines installed, and also Dan is finishing up the welding on my grille shell. He made some panels to fill in the front, and should finish those up this week so that I can take the grille and headlights to the paint shop.

I stopped by my buddys shop Tuesday to drop off Don's headlights, and so far he hasn't touched either body. He says mine will be the quickest because of being further done by us, and that I should have it next week. We'll see. Body shops are notorious for taking super long to get these things done, even if they are a close friend.

Today Don and I are going to try to get some primer on his frame if the weather cooperates.........kinda rainy right now.


Don

Watch out for those twisters don, seems orlando did not fair too well yesterday. It has rained everyday this week here in the north.

Yeah, Cape Coral had lots of damage, cars flipped over, etc. That is only a couple of miles from here. At least no hurricanes so far this year. (knock on wood)


I see you guys are having a car show up your way. Hope you have a good turnout and weather.


Don

Thanks don, i hope it turns out good too, it will be our clubs first show, my buddy is in charge of the bands , we kind of tossed in the car show at the last minute, but so far alot of guys from your side of the state are coming up for it, i have not heard from the poorboys yet, but i know all the draglinks and some of the rumblers are showing up, so hopefully it will be a good show.

Next year, God willing, I'll make it to your second annual show. Good luck with this one.

The rain held out long enough today for Don and me to get some etch primer on his frame. We intended on putting a couple coats of 2 K surfacing primer over it, but just as I was spraying the last section we started feeling rain drops. When that happens in Florida you have like 2 minutes before the downpour comes. So we hustled and got the frame inside before that happened, and it is now sitting in this lovely shade of Army green. I'm trying to talk him into going with this color, but so far no go. (I'm just d*** tired of painting stuff)

Then we were sitting, having a Coke, and my air compressor cycled on and we heard a loud pop and the thing shut down. We ran back and the seperate fuse box I have for the air compressor was on fire !! We got it opened up and luckily the flames went out pretty quick. Evidently the one fuse blew and for some unknown reason caught fire. I thought these things were just supposed to pop and that was it???

Thank God we were there and not outside painting with the door shut because we wouldn't have known it was on fire. This is one reason I always preach to the kids to turn every circuit breaker off in the shop before they leave at night. One time Dans compressor threw a belt and it kept running until it finally fried itself.......so he is pretty good about shutting stuff down now.

Tomorrow Don and I plan to scuff the etch primer and lay on a couple/three coats of surfacer. Then hopefully Monday night we will have all the flaws sanded and puttied out so we can lay on some color.

Don

I vote for that color, that is a real nice shade.

I like the color, but I don't think it goes with the blue that you painted the wheels.
Don, what are you guys doing to those air compressors.....LOL
Brad

If you look at those harley baffles you will see that they are blocked some, I still think you can get by with 1/3rd blockage without to much back pressure.
IMHO
Brad