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Old 01-09-2018, 08:00 PM   #1
Scooby Newbie
Member#: 303367
Join Date: Dec 2011
Default Custom muffler design ideas

I am driving a 2004 FXT.

I recently scored a Chinese 3 inch cat back exhaust. I added a 20 inch resonator parallel to the driveshaft and a Borla pro XS 19 inch muffler. The car is simply too loud. Ive been searching high and low for muffler that will fit in the stock location and be a decent volume and sound deadening. I have not come up with much other then straight through designed mufflers with perforated pipe stuffed with a sound deadening material. Spending hundreds of dollars searching for the right muffler is not appealing. I am a decent welder and fabricator. I am considering building a muffler with same dimensions as the stock unit with a 3 inlet and outlet.

My goal is to be stealth! !!!!

I am in the break-in stage of a new motor and will be getting a pro tune in coming weeks , I am imagining that it will put out approximately 350 wheel horsepower.

Does anyone have any prior experience with such a project? Materials used for stuffing? Shapes for internal baffles that allow for decent flow and excellent noise cancellation?

Thanks for any input you may have,
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Old 01-11-2018, 03:31 PM   #2
Scooby Newbie
Member#: 450737
Join Date: Jul 2016
Chapter/Region: SCIC
Location: SoCal
2012 STi, 99 2.5RS
99 RSTi


Take a look at Summit Racing mufflers made from 304 SS. For the price, you can't build a higher quality, nicer looking muffler, that will sound as good.
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