Series 2 Exhaust

[Lotusfan]

Does anybody in the US have a suggestion on obtaining a new muffler for a Series 2 Seven, or have knowledge on how feasible it might be to cut one open to repack it?  The problem is that the inlet accepts a 1 5/8” pipe and the muffler is 2 3/4” in diameter.  Local exhaust shops aren’t interested when I tell them the tube diameters.  I’m wondering about finding a motorcycle shop.I don’t know for sure if what I have is original but my suspicion that it’s about right for the period and I’d like to keep it similar.

[MV8]

It could cut at the end welds and along the seam lengthwise, then the cover spread just enough to slide over the end cap. Packing doesn't last that long and the muffler design is not very effective. It could be made rebuildable so that cutting and welding is not required. Could also be made a bit larger in od. Hidden inserts for the tip can be made or bought to quiet it down as well.

 

[EdWills]

Hi.

Would a farm tractor dealership be of use?  Many of the farm tractor manufacturers such as Massey Ferguson, John Deere etc., produced silencers in imperial sizes that look like your unit, and they may have the right size for the Seven.   Your unit certainly looks original.  I found a company in the U.K. that produces an oval silencer identical to the unit used on the original Series 3 (not the later round one used on the Twin Cam and Caterham models with the leg protector fitted).  They sell the stainless steel cover, imperial size tubes for welding to the cover, wire wool, internal baffle and fibreglass to pack inside the silencer, all as separate items. A round silencer similar to yours is also available.  See: http://www.jetex.co.uk.   I have used this company, and found them very helpful.  Hope this helps.

[Lotusfan]

Thanks for the replies and suggestions!  I found a local exhaust shop willing to take a look, but they weren’t excited about the 1 1/2 inch tubes.  The tractor suppliers look promising as  a few minutes on the Tractor Supply site shows stuff that might work and look right.  Thanks!

[IamScotticus]

Looking myself for 1 3/4" glass pack type or baffled traight pipes 

[MV8]

53 minutes ago, IamScotticus said:

Looking myself for 1 3/4" glass pack type or baffled traight pipes 

Body length and how big a diameter? 1.75 in and out? Slip fit ends or butt weld? Offsets for a bigger diameter for a more effective muffler?

[Joe Petty]

I built my own exhaust: Maniflow 4-2-1 header, 1 3/4 flex, tractor muffler, various sleeves...

 

I can't find the receipt, but the muffler is 1 3/4 in and 1 1/2 out, the can portion is 13" x 3"  It is a standard tractor muffler that I bought online somewhere.

These mufflers are straight through and kind of loud.  I stuffed some expanded wire mesh inside to baffle to an acceptable level.

 

The flex pipe has sleeves welded on to adapt to the different size pipe and is also welded to the muffler.  The flex pipe and sleeves is 12"

Maybe not the most elegant arrangement, but saves trying to get the pipes to fit and not leak!

 

Not obvious in the picture, but there are 2 short brackets welded to the inside front and back of the muffler can that bolt to rubber mounts to the frame.

 

Good Luck! - Joe

[IamScotticus]

9 hours ago, MV8 said:

Body length and how big a diameter? 1.75 in and out? Slip fit ends or butt weld? Offsets for a bigger diameter for a more effective muffler?

Nor sure. But staying with 1600 and 1.75.

Not using the original muff. Looking for something that won't get caught and rip off my wing.  Wing ripoff proof.

 

Not wanting to hijack, hoping I can find what I'm looking for in the suggestions here.

Edited March 1 by IamScotticus

[IamScotticus]

This is more what I'm looking for,  it's a Harley Davidson cigar muffler.  This is a reproduction from Lowbrow Customs.  1958-72 cigar muffler by Gasbox.  OEM # 65235-58. Out of stock at this time. I haven’t looked everywhere. 

If it's typical Harley,  it's meant to be hidden inside a chrome cover.

Edited March 1 by IamScotticus

[MV8]

No muffler on the side with a transverse offset oval turbo muffler behind the axle would be much more effective. The pipe can be pieced together from mandrel bent, aluminized 1-3/4 header tubing or the caterham tail pipe and muffler could be purchased.

 

For a side muffler, I'd look at a Jones turbo tube. They have a four inch diameter case and come in case lengths from 12 to 24 inches . I'd use a header tube 90 for the turn out, butt welded after cutting the outlet flange off to make room for as long a case as possible, parallel to the seat with a short, shallow bend at the inlet to align with the collector or a short, flex section. Most harley mufflers have a very large od. Glass packs have cases 3 inches of less. Have a shop roll a bead in the end of the turn out/header tube for a finished appearance.

[IamScotticus]

10 hours ago, MV8 said:

the caterham tail pipe and muffler could be purchased.

X-Flow chassis.  Already have one with the rear hanger bracket.  The left side wing lower edge is 2" higher than standard to clear the pipe passing underneath.  Routes under the axle and up under the wing rear.   When I ordered my replacement wing, I neglected to specify and got the standard wing for side exit.

I decided to try side exit going forward.  I learnt hearing protection for the wind would be standard MO.

Edited March 1 by IamScotticus