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Outlander muffler rebuild.


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#1 ozymax

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Posted 25 October 2018 - 06:47 AM

I'm in the middle of doing a "spend no money" rebuild of a 2007 Outlander Max that I've manage to score for our hobby farm.

The muffler was rotted out around the drain plug, so I figured I'd just rebuild it.

I really don't like the noise of the after market mufflers.

 

Thought you might be interested to see just what's inside a genuine muffler.

 

I carefully cut away the rotted skin to reveal the inside components.

 

Inside components.jpg

 

I then made a new particulate capturing chamber out of some sheet steel and pipe.

 

Spark spinner chamber.jpg

 

I then rolled a new outer skin from an old computer tower case. Welding slots were then cut in the correct locations of the components and a new bung hole.

 

Outer skin.jpg

 

Then all the componets were placed in the new skin and tacked in place.

 

Inside placements.jpg

 

Outer skin tacked.jpg

 

Before I weld the front section back onto the muffler I have to finish putting new timing chains in the motor.

I'll post a finished pic of the muffler when I'm done.

thumbs.gif

 

 

 

 

 

 

 

 

 



#2 St8 E

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Posted 25 October 2018 - 08:21 AM

Sucks you live in Australia...I would have given you the, pretty much, brand new stock muffler I took off of mine back in ‘09...

I’m surprised there are that many chambers in there...


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2009 Outlander 800R XT

*12" Hiper Sidewinder's w/ 25" GBC Grim Reapers
*BRP XMR Snorkels/XMR CVT Cover
*Nitroplated Stock headpipe into a Muzzy slip-on 
*Full Tune Monster
*Fox Podium X Front and Rear Shocks
*QSC Primary, STM Secondary
*Precision Steering Stabilizer, Flexx Bars (w/ anti-vibe inserts), Bopp Anti-Vibe stem

*The countless amount of custom "tweaks" that 7Shortmag has done to it!


#3 ozymax

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Posted 25 October 2018 - 08:44 AM

Sucks you live in Australia...I would have given you the, pretty much, brand new stock muffler I took off of mine back in ‘09...

I’m surprised there are that many chambers in there...


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Ha Ha. Thanks for the offer.

That was my delema. Plenty of cans online, but oh the postage costs!!!

Yeah me to. I was really surprised just how much work goes into making these things and according to the stamping on the original skin, they had a patent for the design.



#4 Oh No

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Posted 25 October 2018 - 04:12 PM

Never new a muffler had all those chambers and baffles. Thanks for posting your project.



#5 Skioutty

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Posted 26 October 2018 - 07:00 PM

As always, good work Ozy! 


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#6 25TH INFANTRY

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Posted 12 November 2018 - 02:27 PM

Awesome thread OZ. always wondered what they looked like inside. wouldn't mind using the OEM can just need to rip all that out and build a straight through cage and pack her with exhaust insulation. if one was to do that does the port at the end of the can line up with the front?



#7 ozymax

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Posted 14 November 2018 - 01:12 AM

No. The inlet is offset from the centre and the first divider plate has 2x holes in it and niether of those holes are central.

The end cap tube is in the centre though.

You could make anything work, but the inlet pipe has to be offset to clear the shock.






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