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Reproduction Stihl 084 Muffler

markds2

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As you might have seen, I posted in the 'what's on your bench' thread about the possibility of reproducing the Stihl 084 muffler given the rarity of them and the lack of an off the shelf replacement. I sent the muffler off my 084 (which was in great condition) to my brother in law who is a specialist in industrial CAD design and he has come up with the following example. I must say I'm impressed!

Muffler3.JPG Muffler4.JPG Muffler5.JPG Muffler6.JPG Muffler1.JPG
It has all been designed around being able to be CNC lazer cut and folded out of flat sheet stock leaving just the welding to be done. I'm going ahead with a sample and will keep everyone updated.
 

srcarr52

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You might as well extend the deflector and make the holes underneath as large as possible. Maybe add an optional extra outlet.

Are you planning to have an internal slip in screen like the OEM?

Here's some pictures of one I fixed and modified a few years ago.

IMG_4410.JPG IMG_4411.JPG IMG_4407.JPG IMG_4408.JPG
 

markds2

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Thanks for the reply, I did consider making the exit hole and deflector larger but I wondered that if I kept it a close to OEM as possible it would give everyone the opportunity to modify it to how they liked given that it's hard to go back once the hole is larger. I could even leave the deflector off for those who did want to modify their muffler (the majority of persons in this forum???? ;))

I hadn't planned on a slip in screen at this stage because it would be so difficult to weld in place (I dont have a spot welder, only TIG) but I could investigate options if the consensus is that it needs one.

These are only my reasonings but I would appreciate any feedback and help available.
 

MG porting

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As you might have seen, I posted in the 'what's on your bench' thread about the possibility of reproducing the Stihl 084 muffler given the rarity of them and the lack of an off the shelf replacement. I sent the muffler off my 084 (which was in great condition) to my brother in law who is a specialist in industrial CAD design and he has come up with the following example. I must say I'm impressed!

View attachment 198407 View attachment 198408 View attachment 198409 View attachment 198410 View attachment 198411
It has all been designed around being able to be CNC lazer cut and folded out of flat sheet stock leaving just the welding to be done. I'm going ahead with a sample and will keep everyone updated.
Very cool.
 

MG porting

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Thanks for the reply, I did consider making the exit hole and deflector larger but I wondered that if I kept it a close to OEM as possible it would give everyone the opportunity to modify it to how they liked given that it's hard to go back once the hole is larger. I could even leave the deflector off for those who did want to modify their muffler (the majority of persons in this forum???? ;))

I hadn't planned on a slip in screen at this stage because it would be so difficult to weld in place (I dont have a spot welder, only TIG) but I could investigate options if the consensus is that it needs one.

These are only my reasonings but I would appreciate any feedback and help available.
Screen's are a must around here so I think having the option would be a good thing.
 

Czed

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Thanks for the reply, I did consider making the exit hole and deflector larger but I wondered that if I kept it a close to OEM as possible it would give everyone the opportunity to modify it to how they liked given that it's hard to go back once the hole is larger. I could even leave the deflector off for those who did want to modify their muffler (the majority of persons in this forum???? ;))

I hadn't planned on a slip in screen at this stage because it would be so difficult to weld in place (I dont have a spot welder, only TIG) but I could investigate options if the consensus is that it needs one.

These are only my reasonings but I would appreciate any feedback and help available.
Close to oem is what I'd think will be the most popular.
Everyone has their version of a muffler mod.
But this will give them a great starting point.
 

MG porting

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No problem at all, I've got him looking at how we can do that. I'm also making the external deflector larger so we can make the exit holes underneath larger.
Good deal. Thanks for doing what you are good thinking making saw lover's very happy.
 

markds2

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Good deal. Thanks for doing what you are good thinking making saw lover's very happy.

My wife thinks I have a problem, and can't understand why I have a MS200T, MS261, MS441, MS660, MS661C, Huztl 090 and the 084. And I dont even have a wood burner (will have next season)
 

MG porting

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My wife thinks I have a problem, and can't understand why I have a MS200T, MS261, MS441, MS660, MS661C, Huztl 090 and the 084. And I dont even have a wood burner (will have next season)
Lol. Know the feeling but mine figured out if I have my Saw's then she will get her car restored so it's a trade off plus I end up working on everyone else's Saw's so she can't keep up anymore.
 

srcarr52

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Thanks for the reply, I did consider making the exit hole and deflector larger but I wondered that if I kept it a close to OEM as possible it would give everyone the opportunity to modify it to how they liked given that it's hard to go back once the hole is larger. I could even leave the deflector off for those who did want to modify their muffler (the majority of persons in this forum???? ;))

I hadn't planned on a slip in screen at this stage because it would be so difficult to weld in place (I dont have a spot welder, only TIG) but I could investigate options if the consensus is that it needs one.

These are only my reasonings but I would appreciate any feedback and help available.

I tig weld everything as well. Notice in my muffler mod for the extra outlet I added a screen holder on the inside. It wasn’t hard to weld, just use a stubby back cap so you can get the torch in. You don’t need to duplicate the stock 084 screen holder, just make one like an 066.

I’d invest in a mig welder if you are going to do a bunch of these. That 3” of inside corner on the backside would be a great place for a clean mig weld. I hate tig welding inside corners, so much filler!
 

markds2

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I tig weld everything as well. Notice in my muffler mod for the extra outlet I added a screen holder on the inside. It wasn’t hard to weld, just use a stubby back cap so you can get the torch in. You don’t need to duplicate the stock 084 screen holder, just make one like an 066.

I’d invest in a mig welder if you are going to do a bunch of these. That 3” of inside corner on the backside would be a great place for a clean mig weld. I hate tig welding inside corners, so much filler!

Thanks for the help Mr Carr, I did wonder about changing the configuration of the screen holder but as the exit hole is right up on the top corner of the muffler the stock configuration of the screen holder does allow for more area. All I need to do is make the muffler casing in two parts to allow me to weld it in.
 

srcarr52

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Thanks for the help Mr Carr, I did wonder about changing the configuration of the screen holder but as the exit hole is right up on the top corner of the muffler the stock configuration of the screen holder does allow for more area. All I need to do is make the muffler casing in two parts to allow me to weld it in.

Muffler screen is usually 50% open which is much less in actual flow. As a rule of thumb to make the screen the lesser restrictive part, if possible, I try to have 2-2.5x area of the screen exposed to the outlet size.
 

qurotro

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From the manufacturer stand point this design ain't cheap...
 

MG porting

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