930 Muffler/Silencer refurb

[SteveCarr]

Hello Pelicans!

I rebuilt my 930 engine and gearbox and during this process I had to decide what to do about my crappy exhaust which had been patched up already.

I tried to patch the exhaust but in the end opted for a more radical repair that I thought might be interesting to you Pelicans.

This is what it looked like to start with...


This is another shot to show how naff it looked...



and yet another...


OK so what next... Well the basic parts of it looked OK except for the outer cover which had rusted through. I decided to grind off the outer cover. When I had done this I also decided to make the exhaust flow gas more easily by opening up the holes (note larger holes) and making some other simple modifications...



This is the modified back part of the muffler...



OK so having removed the rotten part of the muffler I needed to replace it with something better. I decided to use stainless steel sheet which I purchased cut to size from Ebay. I prepared the sheet by drilling holes in it so I could simulator spot welds using my MIG welder and Argon gas with stainless steel wire. This is the welding process...



You can see that I started by tacking the sheet whilst I carefully bent it around the exhaust.



Now I am by no means a pro at welding having only a few hours of practice under my belt. This is another shot near the end of welding it all up...



After getting the sheet in place it was a fairly simple job to complete the welding. On completion of the welding I dressed it using a grinder then used a flap wheel on an electric drill to put the final finish on the stainless sheet. This is what it looked like...



Nealry done now I decided to have the rusty parts bead blasted then metal sprayed then sprayed with high temperature paint to finish the job off. This is what the final muffler looked like when fitted on my beautiful 930 engine...



I think it looks pretty good compared to what I started with and it saved me a lot of cash over buying a new stainless exhaust. I was a bit concerned about how much noise it might make but it sounds really great. I hope this thread gives some help to anybody who has a poor condition muffler and wants to have a go at repairing it...

Your comments/observations are welcome but this is my way of giving something back to this forum so I hope you like it!

Steven Carr - 24th Sept 2007