Exhaust DIY Exhaust Pipe

Discussion in '2-Stroke Engines' started by heXed, Dec 29, 2013.

  1. heXed

    heXed New Member

    Just FYI... this fix did not work in the end. :(
    Ok, so I blew an exhaust gasket on my stock muffler and wasn't quick enough to replace it before the gap caused the bolts to loosen holding the muffler on. With the gap in the gasket, I didn't even hear a difference when the muffler fell off, and it was gone when I retraced my path in search. Since I was running with no exhaust (this is my commute, so I couldn't just park :( ), I was given an expansion chamber for Christmas. I was ubber excited as I had been wanting to upgrade anyway, but was very agitated to find that the new pipe started coming apart at the seams in under 30 miles. I took it off and am in the process of refunding it, but that leaves me back to having no exhaust on the motor. So, I needed to come up with something and it couldn't involve welding, milling, or anything that involved more than a drill or handtools...

    Here's what I cam up with...

    DSCN2072.jpg DSCN2078.jpg

    I had the copper tube and washer laying around. The copper is a flexible water heater connector and the washer is just a really big sized washer (I have a bunch that I got to set up a washer game in the yard). I cut the ends off of the copper tube and enlarged one end so that I could use the washer to press it against the exhaust port. It was a trial & error process involving ball & flat hammers and different random objects to use as forms, but it finally took shape. The washer had to be have bolt holes drilled in it and the top had to be cut down so that it would clear the cylinder fins... hack saw and grinder attachment on drill. Here is a pic of what I started with..

    So, test drive.... still spits some oil, but at least it isn't on the wires anymore, lol. It's loud, but I expected that. Most importantly, though... I have good power and am no longer as concerned with dirt and such getting into the cylinder. I may eventually play around with different pipe lengths, as I assume that will change the performance, but I am very happy with my fix.

    I will say, I can't wait to eventually learn to weld. I have so many ideas! In the mean time... point made that you don't have to have a full workshop to come up with something when it's needed. I managed a fix with what I had around and I think it actually turned out quite nice
    Last edited: Jan 2, 2014

  2. heXed

    heXed New Member

    Oh, the wood block... Yeah, so the expansion chamber wouldn't fit on the motor where I had it mounted in the frame. That was a temp fix to raise the motor until I found something better. I am, I guess, also happy to be able to lower the motor back to where it was.

    It's been a good day...
  3. bluegoatwoods

    bluegoatwoods Well-Known Member

    Good job, man!

    I wonder if the corrugations in that copper tubing will have some sort of expansion chamber type effect. It's sure to be different. And the chances that it'll be 'in tune' with your engine would seem to be about zero.

    But it's just possible that it'll create just enough back pressure to keep your engine from spitting out large amounts of unburnt fuel.
  4. Fabian

    Fabian Well-Known Member

    Why is there so much oil covering your engine?

    I run my engine at 25:1 and i only have a few small drops of oil clinging to the bottom of the engine.
  5. wheelbender6

    wheelbender6 Well-Known Member

    Very resourceful. You could probably make a baffle from a beer can if you want a quieter exhaust a bit.
  6. heXed

    heXed New Member

    So, It turns out this was a short-lived solution. The copper didn't seem to do well with the heat/vibration and didn't last. :(
    Back to riding with an open port for a while again.

    Bluegoatwoods: It certainly wasn't tuned to the engine or ideal, but while it lasted, it was definitely an improvement on no pipe at all and honestly seemed better than the stock muffler.

    Fabian: The reason there was so much oil on the engine was from riding it with a blown exhaust gasket and then with just an open exhaust port. Going about 100 miles with no pipe at all definitely lands a great deal of oil/gas on the bike frame and engine.

    I have other thoughts on a diy exhaust but they all involve welding, so I'm at the mercy of money right now to get something else on the motor. Still, being my only means of travel, this motor must keep running, so if anyone has ideas, I'm open....
  7. Fabian

    Fabian Well-Known Member

    If you were riding it with an open exhaust port, your eardrums would have been blasted to pieces (with potential long term hearing loss), not to mention the rest of the neighbourhood.
    A replacement standard exhaust only costs around $15 to $20. A small price to pay to keep your ear drums intact.
  8. bluegoatwoods

    bluegoatwoods Well-Known Member

    It's too bad the copper didn't work. Though I'm wondering just how it could fail. Did it soften up? Maybe burnt through?

    All the same, it's true that a new exhaust for these things is pretty cheap. And that's definitely better than running an open exhaust.

    Sometimes I play with notions of modifying my exhaust. About five years ago now I fabbed up a dual exhaust that almost worked. So if you're still feeling the urge to DIY, I'd understand.

    Post your results. We'll be interested.
  9. HeadSmess

    HeadSmess Well-Known Member

    they arent THAT loud with out the exhaust. i can still hear the cicadas over the roar...i can still hear bats squeaking but, despite a youth spent playing and listening to metal music :) yes, i do have tinnitus, i need a fan to be on when im sleeping...

    i found a welder on the side of the road yesterday :) works, too!

    all i can think of, if you dont have access to much but big washers and a drill... make a stack of washers, spaced out along some fairly long studs... and then try and find a steel aerosol can and mount that over the top of everything... at least it would be some type of baffle, but then again...they arent THAT loud without the muffler! not compared to say, a lil kx80... which is still louder WITH a muffler...

    but, to keep everyone in your street happy...buy a muffler.

    if you know a plumber with a sutable tap, you could try threading the port, aka briggs and stratton style, and simply screw steel plumbing pipe on? some of thes ethings have round ports... theyre even quieter with no muffler if you can get all that goop BEHIND you ;)
    Last edited: Jan 2, 2014
  10. HeadSmess

    HeadSmess Well-Known Member

    oh. copper.

    one, it work hardens, which makes it brittle.

    two, it doesnt have much hot strength.

    it has to be heated until it glows red to anneal it, which is "softening" it again.

    im sure youve noticed coiled copper pipe is very flexible, whereas the cold drawn straight stuff is quite hard... keep flexing the coiled stuff and soon it will be hard as well...

    then chuck in some high frequency vibrations, with only a support at one end...
  11. keatonx

    keatonx Member

    Or he could put the threaded tube on the briggs sausage/pancake style muffler into the hole of that big washer, then flare the end of the tube with a ball peen hammer so it doesn't come out.

    And about that free welder, I might be moving to austrailia now!:jester:
    Or maybe it was a microwave and you took out the transformer lol

    Btw I love the sig, basically sums up everything that I was taught in health class lol
    Last edited: Jan 2, 2014
  12. HeadSmess

    HeadSmess Well-Known Member

    lol, thats a good idea if it will clear the frame!

    its only a stick welder, but seeing as my wizz bang TIG/stick has blown up...very handy :)

    the sig....it had a lot more in it, and after falling over laughing i had to do a lot of editing to get within the character limit! theres 12 points in total ;)

  13. wheelbender6

    wheelbender6 Well-Known Member

    I understand why you did it. It's just more satisfying to fix it with something you have laying around than installing a new part. My wife will never understand that satisfaction.
  14. keatonx

    keatonx Member

    True that, I always end up having more fun on a bike I made out of old junk than one I invested a lot of time/money into. Cuz your expectations are lower, and it's no biggie if something breaks.

    If it's something that won't damage the rest of the engine if it fails (ie. Exhaust), and you don't mind tinkering, why not jerry-rig it?
  15. keatonx

    keatonx Member

    I always find myself up fixing up old motors and cassette players and other things that I find at the dump. Lots of brand new lawnmowers that were thrown out because they wouldn't start, when in the end it was just flooded. If I had the space I would fix them up and sell them. Most of the stuff there still works perfectly. I'm pretty cheap:jester:
  16. HeadSmess

    HeadSmess Well-Known Member

    bins at hardware stores are pretty good too :) it really is amazing how many people cant tell the difference between PREMIX and straight oil... the customer AND the guy behind the counter that considers a fuel tank full of oil as a genuine warranty return... tip...not many places go to the effort of sending all these returns back to the supplier!

    (get friendly with someone that works there and get notified when ever things do come in ;) first in best dressed i say)

    was fixing a lil concrete vibrator for someone earlier... fell on its side. oil out the breather, straight into carb. simple fix. drain the oil out of the bowl. then wash all the oil out of the (paper) air filter... $50 for half hour doing doodly squat :jester: thankfully, cus working on ANYTHING to do with concrete...is the pits :(
  17. heXed

    heXed New Member

    Far too much has been posted to reply line by line... As far as being loud without the muffler.. Yes, it's loud, but not so much when you are riding it. I thought it had a good sound to it, actually, but was told by a friend that he could hear me coming up the road more than a minute away. With the fact that I sometimes have to leave the house at 5am to get to work, it would definitely be better to have an exhaust. I haven't seen the stock mufflers for as little as $15.. more like double that. I was hoping not to pay that much for another stock anything when an upgrade is so little more. Never the less, I can afford nothing at the moment. I took me more than 6 months to find a job (never taken that long), and it's a crappy minimum wage part time cashier position for Dollar General. The place I live costs $500 a month and I make less than $650 a month, so no electric, etc... Working for change, but having to make do with what I have until I can make that change happen.

    As far as the copper, I had no idea if it would work, but I would rather try something than just sit back and whine about what's wrong, and if it had have worked, I would have been super happy. It didn't, so I move on. I may get another pipe whenever I can afford one, or I did notice that O'Rielly's has flexible exhaust tubing for pretty cheap, so am considering that. Alternatively, I've seen exhaust made from electrical conduit and have some of proper diameter. It isn't exactly easy to bend, but I might be able to get something done out of it. Still, I have to figure out how I'll attach a flange to that for attaching it to the motor.
  18. HeadSmess

    HeadSmess Well-Known Member

    you need a mate that will do a favour ;) you might just get lucky if you go hassle a few workshops...any mechanic should have a welder lying around...they might even want an assistant, etc etc etc... hey, one guy round here doesnt mind me using his surface grinder or bridgeport mill...as long as its quiet at the time. he refuses to take money!


    if buying a welder isnt an option...try looking up the "microwave welder". can get away with a pencil lead as an electrode, etc...

    even big car batteries work if you try.

    times are tough in the US,im told. sorry bout that :( maybe if they had kept the CEO wages in check, and kept all them factories they used to make things in... strange how one guy cant pay a power bill, yet someone else can just go buy a lambo....and pay with CASH.... and who does more work? the poor one :( rich a-hole can pay a law firm to tweak his tax return so he pays as little as possible... the law firm makes more from him than what he pays in tax! thats just wrong!

    isnt detroit considered broke? half the streetlights arent turned on, the other half need new bulbs, etc? yet some of the cars that once came from there sell for what some of those guys earn in five years! at least!

    what happened to cincinnati machines?

    technically, i havent worked in 6 months... heh heh heh. still havent resorted to handouts at the dole office but! mow a few lawns...rebuild the odd engine. maybe i should start advertising?
    Holly likes this.
  19. heXed

    heXed New Member

    There are a lot of factors at play when it comes to the current economy. I'll try to keep politics out of the engine pages, lol. But, yeah. I've looked into the microwave method and had two microwaves I had collected with intent to make a welder. I was waiting until I got electricity to rip them apart, but recently sold one of them for some quick cash. Eventually, I may try that. Right now, I'm looking for some car batteries. I've seen where you can restore old batteries using an alum/water mixture, so I really want to try that out. If I can get a couple of batteries, I can charge them with my little generator (two stroke 1200w beast) and give it a try. You mentioned using pencil lead. Would that be a replacement for the "rods"? Does it give a decent weld? I've never heard of this.

  20. HeadSmess

    HeadSmess Well-Known Member

    carbon arc welding. becomes a bit more like TIG, where you need the filler rod. the carbon itself tends to produce the shielding gas.

    probably better to just use standard electrodes, really ;) good old 6013, 2mm if you can find them that thin anymore!

    and be careful with microwave trannies! they spit out unregulated 1000v + normally you rewind the secondary with heavy guage wire, and a lot less turns!

    using a car battery (or 3, really, need at least 30 volts...) you run the current through one side of a transformer, use it as a big inductor. keeps the arc smooth.