How to Make Mufflers

Making a muffler is a rewarding, yet simple process. A lightweight muffler for smaller engines can be manufactured using only a few pipes and a hairspray can. Using a hairspray can allows for easier manipulation of the aluminum and the correct shape for constructing a muffler. In addition, the lightness of a hairspray can allows for the use of JB Weld in securing the project together. A heavier can would cause the welding to rattle apart under stress. These mufflers will retain their structure up to temperatures of 120 degrees Fahrenheit.

Things You'll Need

• Aluminum hairspray can
• Drill
• Needle nose pliers
• Pressure nipple
• Alcohol wipes
• Pipe, ¼ inch diameter, 3-4 inches long
• Curved pipe, ¼ inch diameter, 5 inches long
• Short straight pipe, ¼ inch diameter, 2 inches long
• 2 Rubber fittings, ¼ inch diameter
• JB weld
• Popsicle stick

Instructions

1. Drill a small hole into the center bottom of the can approximately ¼ inch in diameter. Use a wood bit at low speed for safety. Remove the plastic valve and stem using a needle nose pliers. Bend the hole open slightly so it's round and ¼ inch in diameter. At approximately one inch from the bottom of the can, punch a hole and install the pressure nipple. Wash the can with alcohol and put aside.

2. Fit one pipe into the head of the can, placing a rubber fitting around the pipe. Make sure the pipe snuggly fits and no air can escape the passageway in the joint. This is where the exhaust leaves the muffler unit. A curved pipe can be used if necessary.

3. Fit the smaller pipe into the bottom of the can. Again, place a rubber fitting around the pipe. This is called the inlet pipe. Ensure no air can escape the area where the pipe and the can meet.

4. Attach a curved pipe to the inlet pipe in the bottom of the can. The curved pipe should fit inside the inlet pipe. Using a popsicle stick, spread a small amount of JB Weld around the pipe joint. Make sure the JB Weld is smoothly applied with no clumps. Set aside in an upright position and allow to cure overnight.

5. Clean the pipes with alcohol. Allow to dry and fit onto the engine in the desired location. Attach the inlet pipe to the engine using screws or fasteners. Use a cable tie attached to the engine and hung along the exit pipe. This allows the muffler to maintain a free mount for safety.

Tips & Warnings

• Be sure to always wear safety goggles when drilling into the aluminum can. Be sure the hairspray can is empty before drilling, even a small amount of material will cause the can to explode.

Resources

• Mousse Can Muffler
• Building a Can in Can Muffler