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Reproduction Stihl 084 Muffler

Discussion in 'Chainsaws' started by markds2, Sep 9, 2019.

  1. markds2

    markds2 Super OPE Member

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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.
     
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  2. markds2

    markds2 Super OPE Member

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    @mdavlee can you offer your opinion given you have already worked hard on making your own?
     
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  3. srcarr52

    srcarr52 We can't stop here, th1s is bat country!

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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
     
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  4. markds2

    markds2 Super OPE Member

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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.
     
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  5. MG porting

    MG porting Pinnacle OPE Member

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    Very cool.
     
  6. MG porting

    MG porting Pinnacle OPE Member

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    Screen's are a must around here so I think having the option would be a good thing.
     
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  7. mdavlee

    mdavlee Hillbilly grinder

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    That would be much easier than how I did them. I rolled 3 sides of it and then welded it to keep from having so many seams.
     
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  8. markds2

    markds2 Super OPE Member

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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.
     
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  9. Czed

    Czed Mastermind Approved!

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    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.
     
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  10. MG porting

    MG porting Pinnacle OPE Member

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    Good deal. Thanks for doing what you are good thinking making saw lover's very happy.
     
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  11. markds2

    markds2 Super OPE Member

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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)
     
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  12. MG porting

    MG porting Pinnacle OPE Member

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    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.
     
  13. srcarr52

    srcarr52 We can't stop here, th1s is bat country!

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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!
     
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  14. markds2

    markds2 Super OPE Member

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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.
     
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  15. srcarr52

    srcarr52 We can't stop here, th1s is bat country!

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    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.
     
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  16. qurotro

    qurotro Cookie Cutter

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    From the manufacturer stand point this design ain't cheap...
     
  17. markds2

    markds2 Super OPE Member

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    We shall soon see.....
     
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  18. markds2

    markds2 Super OPE Member

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    Here is the redesigned deflector and the proposed screen holder. I'm getting this design priced in both 1.6mm and 2mm mild steel today. Also, how would people think about an s/s version?

    Muffler12.JPG
    Muffler9.JPG Muffler10.JPG Muffler11.JPG
     
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  19. MG porting

    MG porting Pinnacle OPE Member

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  20. drf256

    drf256 Dr. Richard Cranium (“RC” to Muh pals)

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    Looks great.

    Where is the pocket for the muffler bearing?
     
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