2 stroke mufflers

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Had some one call and want to know if I could weld some 24 gauge mild steel pipe, told them sure loaded my xmt and foot pedal in ny rig.... Got there they wanted me to weld up these mufflers. They had all the parts cut out I just had to tig it all up. Got done with the first set and the guy told me he wanted 9 more sets. They are off a McCullough 4 cylinder 2 stroke gyrocopter engine. Sent from my HTC One X using Tapatalk
Reply:I imagine you really have to know what you are doing to design an exhaust system and get the most out of it.
Reply:Tried to copy the old one as close as possable. Only had the one to go off. They cut the other one apart to make templates for the parts. The old one was galvanized that had been brazed together. It still had chunks of propeller in it from the crash it was in. Sent from my HTC One X using Tapatalk
Reply:Nice job gotta like it. YeAh 2stroke exhausts are super sensitive to changes I know with my sleds and bikes I can gain 5hp  with a simply exhaust swap
Reply:Muffler is not really the right word, it is a tuned exhaust designed to help the engine breathe better using reflected pressure pulses, if less noise is desirable there's usually a common fibreglass packed muffler after the tuned pipe. Nevertheless, that's some nice work.Looking at the pipe design, I'd say it's more designed to be cheap and easy to manufacture, than to produce maximum power. On the other hand, I'm guessing that's a large displacement low rpm engine designed to be reliable, and no matter how good the pipe is there just isn't a whole lot of exhaust pulse energy to work with on that type of engine. Another matter on a high rpm race engine...Some tuned pipe porn, starting about halfway down: http://www.pvlsverige.se/vrm/avgas/avgas.html
Reply:9 more sets?Does he crash alot??
Reply:howd that 24g weld up?R.T. Welding LLCOn Site ServiceColumbus, NJ
Reply:Very cool, looks good. Any close up shots of your welds?G-son, nice link. Any way to translate to English? Thanks
Reply:Originally Posted by sqznbyG-son, nice link. Any way to translate to English?
Reply:This link should give you it all translated with google translate: http://translate.google.com/translat...html&sandbox=12 stroke expansion chambers are an art....actually, more like a black art.
Reply:for anyone who is truly interested in designing these, the first thing you do is obtain a copy of Two Stroke Tuner's Handbook.  I paid $100 for my copy several years back.  I see they are much higher now but there is pretty much everything you need to know jammed into that little paperback book.  You will read it 3 times and still not know it all.
Reply:what size tungsten works best for the 24g. .040 or 1/16?R.T. Welding LLCOn Site ServiceColumbus, NJ
Reply:Have been using .040 %2 cereated with a standard collet body. Have the big dial at 65 amps and work the pedal a lot. I started out with 1/16 er70 filler but moved to 3/32 and have been weaveing. Seems a lot more forgiving with poor fit ups. Makeing parts from peaces that were all mashed up in a crash has not been fun. Sent from my HTC One X using Tapatalk
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Reply:Darlington, very cool and loved your video of that project.  In fact, I enjoy all of your welding videos!  Would love to see more of your BIG STICK electrodes you use on some projects.  I believe you used some BIG 3/16" 6013's on a project a while back with your awesome restored Lincoln engine drive welder!   Please keep 'em coming and thank you for sharing!!!!Lincoln Power Mig 216Lincoln AC/DC-225/125Miller  625 X-Treme PlasmaMiller 211 Forney 95FI-A 301HF 91110Victor Journeyman O/PMilwaukee DaytonMakita  Baileigh NRA Life Member
Reply:I have got a bunch or requests for big rods, once it warms up a bit il get make some videos. Working out side sucks when it's 0. Sent from my HTC One X using Tapatalk
Reply:Here is a link to the video about the mifflers, will get a time laps of makeing one up soon.   Sent from my HTC One X using Tapatalk
Reply:If he wants 9 more sets this could turn into a nice little side gig.  You could probably sell some on eBay too.  Guess it depends on what the factory replacement ones go for vs how much yours cost you to make.  I grew up riding dirtbikes and I'm a huge fan of 2 strokes.  This is a little OT but I wanted to share this video I found recently: Last edited by dhem; 02-11-2014 at 06:24 PM.Reason: spellingMiller Dynasty 200 DXBuildPro TMA52238 (38" x 22")Miller MP-10 & Jackson Nexgen EQC20 Ton Press & Swag HD Press Brake
Reply:That's looks like a lot of work.  Did you get to try out the flying machine ?
Reply:Originally Posted by dhemIf he wants 9 more sets this could turn into a nice little side gig.  You could probably sell some on eBay too.  Guess it depends on what the factory replacement ones go for vs how much yours cost you to make.  I grew up riding dirtbikes and I'm a huge fan of 2 strokes.  This is a little OT but I wanted to share this video I found recently:
Reply:Originally Posted by dhemIf he wants 9 more sets this could turn into a nice little side gig.  You could probably sell some on eBay too.  Guess it depends on what the factory replacement ones go for vs how much yours cost you to make.  I grew up riding dirtbikes and I'm a huge fan of 2 strokes.  This is a little OT but I wanted to share this video I found recently:
Reply:Customer texted that the mounting brackets are all in the wrong spot, his mistake thankfully have to go through and grind off 40 brackets and weld on 40 more. Thankfully its time and materials Sent from my HTC One X using Tapatalk