INTERNAL STRUCTURE OF EXHAUST 1976 SUZUKI GT250A

[TJCOOL]

hi

another daft q;

my right exhaust pipe, in fairly good nic, has some loose bits floating around inside I cannot get out. I assume, without proof (websters dictionary) that this may be some of the internal structure that may have deteriorated.....now the baffle is cleaned and has been (actually it will be - no porkies here please) re-packed..will I be able to use this right exhaust with any noticeable effects on performance or sound? Will it hurt the engine at all?...finding a good exhaust is hard and getting nos is extortionately priced...


thanks

TJ

[GTandcbr]

Have a look here it will give you an idea whats inside.http://www.kettleclinic.co.uk/kcforum/v ... =16&t=9222" onclick="window.open(this.href);return false;" onclick="window.open(this.href);return false;
You will find one of those internal dividers that are only tacked on has broken loose. I have the same problem but it doesn't have any affect on the engine in my case

[TJCOOL]

Have a look here it will give you an idea whats inside.http://www.kettleclinic.co.uk/kcforum/v ... =16&t=9222" onclick="window.open(this.href);return false;" onclick="window.open(this.href);return false;" onclick="window.open(this.href);return false;
You will find one of those internal dividers that are only tacked on has broken loose. I have the same problem but it doesn't have any affect on the engine in my case

so that's what's inside?...ok then...thank you..good to know it won't hurt anything and I suppose one would have to be very skilled to disassemble an exhaust for repair....maybe I'll attempt it one day..if not to repair to remove all that fiddly bits knocking around...that was a great pic..

tj

[Jimroid]

Wow! Not exactly what I expected for internals on those mufflers. I am not a member over there, but if someone could get baffle locations and dimensions, I could build some cool pipes. What model was the sliced pipe of off?

[TJCOOL]

Wow! Not exactly what I expected for internals on those mufflers. I am not a member over there, but if someone could get baffle locations and dimensions, I could build some cool pipes. What model was the sliced pipe of off?

build your own pipes? how? have you done this before? if so any pics?

[akendall1966]

For your education.....

Fabricating a chamber form lots of conical sections rolled from sheet metal
https://youtu.be/d9n6do0__Rs

Hydroforming - realy tricky to do well as you can't shrink the metal so you get creases it you haven't got the flat form just right
https://youtu.be/Me1ATMlk4ac

Pressing (how the factory do it) - couldn't find a exhaust specific video, but same principals apply big press and die turn flat sheet metal into a shape of half the exhaust, two halves welded ed together with internal bits inside. The kettle clinic link the exhaust has been cut open or or less along the weld line so your looking at the shape that comes out of the press tool with the internal baffles added
https://youtu.be/BLuoIlefo80

[Jimroid]

It would be pretty straight forward to duplicate a stock muffler functionally if you had some dimensions. And yes you can make real chambers of course,that is time consuming.