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Muffler design... just for fun


Chapap

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What are some neat muffler designs out there? No particular reason for asking. I just think it's neat. It's tough to find many cutaway views, but there seem to be 3 types. The baffle where there's an inlet, then a sheet metal labyrinth of sorts, then the outlet. Then there's the style where there's a clear path with pipe, but it snakes back and forth thru some chambers. And of course there's the glass pack style. Then to add, what makes a resonator different?
 


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If you want to learn about mufflers, read one of David Vizard's books on building for horsepower. He talks about how the various muffler designs look from a flow standpoint, and what that means for backpressure and reflected pressure waves. Look at Dynomax Super Turbo for an example of a free flowing muffler design that flows well and does not produce undesired reflected waves.
 

gaz

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@Chapap
My favorite design is the Borla XR1 multi-core; it wasn't originally called multi-core but the now offer both it and a new line called Sportsman, which is essentially a strait though design, while the multi-core uses 3 or 4 sections of tubing to comprise the inner core. It is one of the only exhaust systems proven to make more HP that the strait pipe in the same ID.
 
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gaz

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Yes, like this...use this to make less power than a Borla XR1 multi-core muffler 🧐
I'd be interested in seeing some 3rd party dyno sheets comparing a straight pipe/glasspack vs one of the multicore mufflers installed on something.. if you can find some.

seems like 270$ is the cheapest option.. 10x the price of the muffler I'm putting on my '96 lol.. same grade of stainless too
 

Chapap

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I know X and H pipes help with scavenging and flow and all that if done correctly. There's also header lengths and all that. I just got to looking at my big diesel muffler (like 18" diameter x 3') and was wondering what was in there. I always thought a muffler's goal was to absorb all the engine pulses to make it quieter... and be as non-restrictive as possible while doing it. I imagine that's about all a turbo'd engine muffler does.
 

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What I did with both mine and dad’s 5.0 Rangers was to use a crossover muffler. There’s not a lot of those out there (most dual in, dual out mufflers don’t seem to have a crossover so you need an X or H pipe for scavaging, or at least they say you should. Magnaflow makes a stainless crossover that basically looks like two glass pack tubes crossed like an X, I’ll have to find the pic. I did an 18” long one. With headers and high flow cars with 2.5” tube, it’s a bit loud. My friends hear me coming. As in my friend Lisa knows when I pull into the restaurant she works at when she’s all the way back in the kitchen with rock music playing over the kitchen noise. It’s not obnoxious, but it’s definitely not quiet.

Other than that, I’m kinda partial to the Flowmaster 40 and Super 40 series mufflers.
 

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I know baffle design and how they are oriented makes a difference. That is why some glass packs actually reduce horepower. Generally, it's the cheap ones that cause a problem. Something about how the baffles are oriented. It might be because the baffles stick out into the exhaust flow instead of into the media.
 

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Chapap

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I saw a pic of this twister muffler. No clue what to think what it does... but it's neat.
Screenshot 2024-06-20 120358.png
 

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Spintech mufflers look interesting.
I'd like to see the lid. If the top is tight to the swirls it would be dead air inside IMO.
 

rusty ol ranger

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