ShopTalk Forums | Aircooled VW Tech & Restoration Help

Tonight's progress. On the way home I picked up 10' of galvanized conduit with a 1" ID. Then I cut a swatch of 1/4" steel plate and made a flange.

Tomorrow I'll start cutting and welding the conduit so it goes where I need it to go. I don't have a tubing bender, but I can make wedge cuts in the conduit to get it to go around corners.

The conduit was inexpensive. The 10' plus some m6x100 bolts was just under $11 with tax. I can live with that. The 1/4" plate was a left-over from something. That's why I don't throw out the scrap bits.

Couple more...

On the exhaust systems I've seen they just used threaded 90's and like fittings, a 1-1/4" schedule 80 pipe would be pretty fun to bend w/o a very nice bender.

I need to practice my welding skills anyway. We'll see how it comes out. It isn't like the material is expensive ...

Max

Use plenty of ventilation when welding galvanized materials....

Dale

You betcha.

I got three corners done tonight ... and ran out of shielding gas.

To be continued (when the welding supply place opens tomorrow) ...

Max

on galvanized stuff.. grind off the surface galvanization around the area you plan on welding. Have a fan blowing the smoke away from your face but not directly at the weld so it won't blow away the shield gas.

OK, done for today. So far so good.

As you can see, my pipe now goes all the way to the door where I poked a hole for the last bit of pipe.

The problem now is noise. It's quite loud.

I did remove the muffler so I could do a flange. But this will be too loud for the neighbors, particularly at night.

I plan to take the end under the sliding door to exit outside. Now I need a muffler.

Ideas?

Max

I believe in very beginning I recommended adding a FLANGE to the OUTLET of the MUFFLER and to take pipe out from there.....

Dale

Dale M. wrote:I believe in very beginning I recommended adding a FLANGE to the OUTLET of the MUFFLER and to take pipe out from there.....

Dale

True. But the flange is currently holding up the pipe. I think the original muffler would have just folded up under the weight.

Max

Well, I really needed to run the compressor tonight. So I rigged up a temporary muffler.

The bottle actually made quite a difference, although I had to hold onto it to keep it from getting pushed off the pipe.

And it took several minutes for the pipe to begin warming up.

Max

And Dale, I will take a shot at using the original muffler. Looks like I'll have to drill a second set of holes to attach my flange.

Max

Well, I got the muffler problem solved. Turns out an old tire carcass soaks up a lot of noise.

The white hose is just something I had laying around. I'll pick up something that fits the pipe better tomorrow. Turns out the pipe just doesn't get much more than warm at the end. I ran it for 20 minutes and could easily hold it with my bare hand.

Max

Just a thought.. How would a bucket of water work as a muffler? Like putting the end of hose in a 20 gallon bucket filled with water?

You have to be careful about back pressure. small engines such as that can easily burn valves due to exhaust issues.