Reproduction Stihl 084 Muffler

[markds2]

Looks great.

Where is the pocket for the muffler bearing?

I'll have to check with him...I notice it's also missing the muffler ring locating pin.

 

[MG porting]

Looks great.

Where is the pocket for the muffler bearing?

 

[Carhartt]

Looks great.

Where is the pocket for the muffler bearing?

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Oh this is a turbo muffler???

 

[Lightning Performance]

I'd extend the outlet scope a bit longer, my 2ct.

If you want to send a few here or more I can finish them with my mig. I have an 084 with the nice oe nos muffler to fit them up. I don't need one but many guys here do and my welder is ready. PM if your interested.

 

[markds2]

I'd extend the outlet scope a bit longer, my 2ct.

If you want to send a few here or more I can finish them with my mig. I have an 084 with the nice oe nos muffler to fit them up. I don't need one but many guys here do and my welder is ready. PM if your interested.

Thanks for your interest Kevin, the first step for me is to get a price for the CNC work and material (still waiting on this) and then get a prototype stitched together using my TIG. I'd like to keep the welds as small and as tidy as I can but it will be a weigh up between this and the time it takes. I also intend to use my OEM muffler as a template to make a jig up so I can hold the pieces together while I weld, given that the relationship between the cylinder mounting and the two mounts on the crankcase is critical.

Your offer is certainly appreciated and could be a very good way to keep costs down for US based members. I'll keep you posted.

 

[mdavlee]

Thanks for your interest Kevin, the first step for me is to get a price for the CNC work and material (still waiting on this) and then get a prototype stitched together using my TIG. I'd like to keep the welds as small and as tidy as I can but it will be a weigh up between this and the time it takes. I also intend to use my OEM muffler as a template to make a jig up so I can hold the pieces together while I weld, given that the relationship between the cylinder mounting and the two mounts on the crankcase is critical.

Your offer is certainly appreciated and could be a very good way to keep costs down for US based members. I'll keep you posted.

I had to grind the mating surfaces flat in a big sander to make them flat after welding. That’s the worst part to me. And that was at 35-45 amps at the most with a tig rig.

 

[markds2]

Well chaps, I got some pricing back from the manufacturer and based on a production run of 30 mufflers we're looking at around $175USD each (subject to confirmation) plus freight to the US (which would be about $35USD). How does that stack up? I've got a prototype underway in 2mm mild steel and I'll post some pictures once I have something in front of me.

 

[srcarr52]

Are you planning on making the bolt together flange part thicker than 2mm? I think you'll find it will warp a far amount when you weld it and you'll have to belt sand it back flat.

 

[markds2]

Are you planning on making the bolt together flange part thicker than 2mm? I think you'll find it will warp a far amount when you weld it and you'll have to belt sand it back flat.

On the prototype yes, but this can be changed for production. What I am doing is making a jig up, in this jig, the flanges will be clamped between 2 bits of 8mm thick steel while welding, holding everything exactly in place. I'm hoping this reduces distortion to a minimum leaving only a minimal amount of sanding needing to be done.

 

[mdavlee]

On the prototype yes, but this can be changed for production. What I am doing is making a jig up, in this jig, the flanges will be clamped between 2 bits of 8mm thick steel while welding, holding everything exactly in place. I'm hoping this reduces distortion to a minimum leaving only a minimal amount of sanding needing to be done.

I tried that. It still needed a good bit of sanding. I stacked 4 flanges together which would have been 15-16mm. I had mine cut out of 10 or 11 gauge.

 

[markds2]

I tried that. It still needed a good bit of sanding. I stacked 4 flanges together which would have been 15-16mm. I had mine cut out of 10 or 11 gauge.

I really appreciate the help Mike, will take that on board and see how we go.

 

[mdavlee]

I really appreciate the help Mike, will take that on board and see how we go.

I tried several things and none of them seemed to help much besides weld at the lowest amps possible.