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Thread: Repacking the muffler

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    Darth Vader steveg's Avatar
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    Repacking the muffler

    Here's an interesting thread on repacking a Lotus Elan muffler with a Brit product - Acousta-Fil:
    http://www.lotuselan.net/forums/lotu...er-t36438.html

    My Moss replacement, which had been used for several years, had fiberglass packing in the front 2" or so but was otherwise empty.
    83 - 85 DB in spirited driving.
    MufflerBody.jpgMufflerFront.jpg

    I've ordered the product from the aptly-named DemonTweeks.com and will follow up with the installation.
    Last edited by steveg; 01-13-2018 at 10:04 AM.
    Steve Gerow
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    Maker of most complete Big Healey rear disc kit
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    Luke Skywalker RAC68's Avatar
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    Re: Repacking the muffler

    Hi Steve,

    Very interesting and I know a friend that will be as well. Looking forward to hear about your experiences in this area. I am always interested in Fixing or making rather than buying.

    Ray(64BJ8P1)

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    Darth Vader John Turney's Avatar
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    Re: Repacking the muffler

    Interesting. I recall looking into the end of my Moss replacement muffler and seeing no sign of any packing.
    John, BN4

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    Yoda glemon's Avatar
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    Re: Repacking the muffler

    I remember reading a story in Road & Track magazine many years ago about some guy's first MG TC, he talked abouthow the sports car guys would pull the stuffing out of the mufflers with a bent wire hanger to get a more sporting exhaust note. I have never tried stuffing or unstuffing, but it is good to know a man on a budget has options. Certainly much better than tuning the "engine sound" that some modern cars play through their sound system.

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    Jedi Knight DerekJ's Avatar
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    Re: Repacking the muffler

    I have the DWR side exit exhaust which has got louder to such an extent its right on the scrutineering noise limit of 105 db. They are expensive to replace so I'm interested in the re-packing option. BTW Demon Tweeks is a long established, very successful UK speed shop. Its owners race some very expensive classic cars including a Maserati 'Birdcage'.

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    Yoda GregW's Avatar
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    Re: Repacking the muffler

    I had a Micron exhaust on one of my motorcycles. It was designed to be repacked in that it didn't use rivets but stainless screws. Take 4 screws off and the core would slip out. I repacked with long strand stainless wool. Micron's website.

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    Yoda Randy Forbes's Avatar
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    Re: Repacking the muffler

    Supertrapp mufflers are another of the repackable variety, among the ability to tune for high end power or low end torque by adding/subtracting the number of outlet discs.

    A novel approach, once favored by the bulk of serious autocrossers; I have no idea what the in thing is nowadays.

    SuperTrapp: http://supertrapp.com/product_sections/auto/index.asp
    http://www.britishcarforum.com/bcf/image.php
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    Darth Vader Michael Oritt's Avatar
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    Re: Repacking the muffler

    Randy--

    There was a Supertrap on my Courier when I bought it. It made the car (MGA engine) sound like the typical fart can-equipped Honda Accord that flat-hatted kids seem to love. I removed it in short order.

    Think about meeting at Sebring this March 1-3....

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    Re: Repacking the muffler

    Does stuffing steel wool down the pipe of my Bugeye in high school to pass inspection count? Made some pretty sparks when I got on it after the inspection was done.


    Rick

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    Re: Repacking the muffler

    don't use steel wool. not a good idea.

    a few years ago i had a 66 vette that i put side pipes on. wow were they loud. the whole car would resonate and vibrate. even with the top down you could not hear yourself think.

    i went out and bought a bag of scouring pads. they are stainless steel and do not rust. first i drilled a hole in the pipe before/after the muffler chamber. ran a screw that would go all the way to the other side. then i stuffed in one ball in each side. then 2 balls and then 3. i ended up pulling the last one back out and keeping just two in there. then i drilled and put another screw behind them. they never blew out and really made the car a lot quieter. at idle it sounded more like the mufflers that were on it to begin with. it was a little louder under acceleration but nothing unbearable.
    i had read where guys had taken off their mufflers off and put the balls in the down tube. they said it made for a better / different sound. i never tried that. i was happy with them behind the muffler.

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    Darth Vader steveg's Avatar
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    Re: Repacking the muffler

    Quote Originally Posted by DerekJ View Post
    I have the DWR side exit exhaust which has got louder to such an extent its right on the scrutineering noise limit of 105 db. They are expensive to replace so I'm interested in the re-packing option. BTW Demon Tweeks is a long established, very successful UK speed shop. Its owners race some very expensive classic cars including a Maserati 'Birdcage'.
    Demon Tweeks just sent me a 538 page catalog for rainy-day reading. Their name has got to be a marketing masterpiece! Roger Corman (I Was a Teenage Frankenstein) would approve - IIRC he considered a good title to be 80% of the marketing!
    Steve Gerow
    Altadena, CA, USA
    Maker of most complete Big Healey rear disc kit
    Check out my galleries:
    http://www.pbase.com/stevegerow

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    Yoda HealeyRick's Avatar
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    Re: Repacking the muffler

    Quote Originally Posted by steveg View Post
    Demon Tweeks just sent me a 538 page catalog for rainy-day reading. Their name has got to be a marketing masterpiece! Roger Corman (I Was a Teenage Frankenstein) would approve - IIRC he considered a good title to be 80% of the marketing!
    Agreed, very cool name and must have worked since they've been around since the early 1970s. IIRC they were primarily a Mini supplier in their early days.


    Rick

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    Re: Repacking the muffler

    Demon Tweeks .....theres a blast from the past for me . I remember buying a cherry bomb muffler for my Ford Fiesta XR2 from them way back 35ish yrs ago when I used to live in the UK . They were located in Chester which was just a quick drive for me to go to the store . They were the go to guys for performance tuning parts for many cars .
    "If it aint broke ....dont fix it "
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    Re: Repacking the muffler

    The muffler I bought for my TR3 was too long so I cut out a section. Full of fiberglass stuffing. I put it all back in and welded it back together. It sounds good and does not leak! I never expected to find so much stuffing in there. I do wonder how long it will last.

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    Yoda Randy Forbes's Avatar
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    Re: Repacking the muffler

    Quote Originally Posted by Michael Oritt View Post
    Randy--

    There was a Supertrap on my Courier when I bought it. It made the car (MGA engine) sound like the typical fart can-equipped Honda Accord that flat-hatted kids seem to love. I removed it in short order.

    Think about meeting at Sebring this March 1-3....
    Absolutely!

    Yes, I said the SuperTrapps were popular, I never said they sound good

    (press your hand tightly over your mouth and blow; THAT's what a SuperTrapp sounds like!)

    I once saw a pair of them on an M Coupe, but years later when I worked on that car for another owner, they were long gone.
    http://www.britishcarforum.com/bcf/image.php
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    Darth Vader steveg's Avatar
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    Re: Repacking the muffler

    Current build status - building the muffler while awaiting the Acousta-Fil from Demon Tweeks.
    I used reducers from the auto parts store as slightly-bell-mouthed connectors for the internal perforated tubes.
    The internal locator piece is 1-1/2" x 1/16" aluminum from the hardware store. Screws are 10-32 x 3/8" SS threaded into the aluminum.
    MufflerBellConnectors.jpgMufflerEndCap.jpg
    I staked the bell connectors in as I don't yet have welding.
    MufflerEndPartialInstall.jpg
    Tomorrow will fit more screws into muffler body.
    Muffler ends were enlarged to fit header connectors.
    Steve Gerow
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    Maker of most complete Big Healey rear disc kit
    Check out my galleries:
    http://www.pbase.com/stevegerow

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    Yoda Randy Forbes's Avatar
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    Re: Repacking the muffler

    I don't think the aluminum will stand up to the temperature, leaving the screws to fall out.

    Steve, I think it's about time for you to step up to a MIG welder (just think of what you can accomplish then!)! Check the classifieds (Craig's list, ebay) for a good used Miller, Lincoln, or even Century.

    If you're dead-set on screws, to be able to have future access, change out the aluminum to steel__and a little thicker to get another thread or two in there wouldn't hurt either.
    http://www.britishcarforum.com/bcf/image.php
    57 Healey BN6L-942 Wine Red/Honey Tan
    99 BMW M Rdstr Cosmos Black Eurosport Twinscrew Supercharger
    01 BMW M Rdstr Steel Gray Performance Center (factory) Delivery
    11 X5 35i Sport Deep Sea Blue Metallic Wife's Turbo Hauler

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    Darth Vader steveg's Avatar
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    Re: Repacking the muffler

    Quote Originally Posted by Randy Forbes View Post
    I don't think the aluminum will stand up to the temperature, leaving the screws to fall out.

    Steve, I think it's about time for you to step up to a MIG welder (just think of what you can accomplish then!)! Check the classifieds (Craig's list, ebay) for a good used Miller, Lincoln, or even Century.

    If you're dead-set on screws, to be able to have future access, change out the aluminum to steel__and a little thicker to get another thread or two in there wouldn't hurt either.
    When/if the aluminum poops out, will switch to stainless sheet - for which I need to find a source.

    Concerned about regular steel corroding away. Whatever I build needs to be able to be disassembled to be repacked.

    Addendum: Read up on aluminum melting point; bought some SS sheet and will redo and follow up.
    Last edited by steveg; 01-16-2018 at 10:29 PM.
    Steve Gerow
    Altadena, CA, USA
    Maker of most complete Big Healey rear disc kit
    Check out my galleries:
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    Yoda GregW's Avatar
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    Re: Repacking the muffler

    Quote Originally Posted by steveg View Post
    will switch to stainless sheet - for which I need to find a source.
    Was going to mention Industrial Metal Supply, just off the 5 and Sunland Blvd. 140,000 sq ft of candy, er, metal.

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    Darth Vader steveg's Avatar
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    Re: Repacking the muffler

    Quote Originally Posted by GregW View Post
    Was going to mention Industrial Metal Supply, just off the 5 and Sunland Blvd. 140,000 sq ft of candy, er, metal.
    That's where I went.
    Steve Gerow
    Altadena, CA, USA
    Maker of most complete Big Healey rear disc kit
    Check out my galleries:
    http://www.pbase.com/stevegerow

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