How hard is it to weld on a new muffler

[FJsnoozer]

Don't go flow master. They sound like crap.

Straight 6s deserve a straight through muffler. A magnaflow will sound nice, be quiet at idle and have a nice tone at open throttle. You can buy them in stainless too. Dynomax ultra flows flow even better and are a at quieter.

"Thrush" and turbo style mufflers might sound like they are made for power, but they are not. They are a classic perforated design that will be very close to a stock replacement in the way of power and sound.

 

[thetoyotaman]

I'm not interested in anything louder, but would like factory durability and good flow.

 

[Bruzzi]

You could just go this route...


http://www.ebay.com/itm/TOYOTA-LAND...ries&hash=item519ebe801e&vxp=mtr#ht_500wt_922

 

[FJsnoozer]

One of the best mufflers made is the borla product,

I've seen flow masters rot out inside and welds break then rattle.

Borla xs actually made the most HP of all of these despite being the quietest. ( the warlock with the built in cutout actually made most peak power with the cutout open.
Mind you these tests were done on a 370 rwhp all motor v8.

 

[69fj4069]

I am pretty happy with my thrush "turbo" muffler. It sounds really good and I think in 2 1/2" it flows well enough for my 2f. I just orderd the longest one because I wanted it to be as quiet as possible. Also they are reasonably priced.

 

[StaleAle]

I suggest you rethink routing it straight out the back like that. You're not going to like breathing those fumes coming in the back and eddying behind the windshield. I'd re-route it to the side, just behind the rear tire.

 

[Pin_Head]

Can you weld on the aluminized steel pipe?

I have never welded any, but from what I have seen by watching the muffler guy change the muffler on my wifes car, they just welded it without any obvious preparation.

 

[69fj4069]

I welded the aluminized tubing without doing any prep. But I used flux core so that may be different than using hard wire.

 

[saryon7]

If you don't want to worry about the welding, another option is to just bring it to a shop that works with metal and have the pipe expanded. This allows you to just slip it over the other pipe and put an exhaust clamp on it. It shouldn't cost too much because it takes all of about 20 seconds to do it. I do it all the time at the school where I teach.

 

[reddingcruiser]

Welding 101

My 2 cents......I have been welding since I was 16 (I'm much older now) and I've found it's largely practice, patience, preparation and education. If you understand some basic metallurgy, what is really happening during the welding process, and which processes work best in specific applications - you'll do fine. The aluminized coating on exhaust tubing can be a bit of a challenge for a novice if you are NOT using a wire feed process with a shielding gas.

 

[thetoyotaman]

One of the best mufflers made is the borla product,

I've seen flow masters rot out inside and welds break then rattle.

Borla xs actually made the most HP of all of these despite being the quietest. ( the warlock with the built in cutout actually made most peak power with the cutout open.
Mind you these tests were done on a 370 rwhp all motor v8.

That Hooker MaxFlow is about half the price of the Borla. Anybody know anything about it?

 

[FJsnoozer]

It's half price because it's probably not full rig stainless and it is made in Mexico.

Can you get a dynomax for a fair price through summit?

 

[thetoyotaman]

I haven't checked. I'm actually thinking about starting with a generic low cost muffler to practice the welding on and if I beat it up off road it wont be that big a deal. I did cut the flange off the old muffler and am cleaning it up.

 

[thetoyotaman]

Well after inspecting the economy mufflers I noticed that when you look inside them they restrict significantly whereas the turbo mufflers dont. So, I'm thinking that my economy muffler to practice on might be a Thrush Turbo or Raptor muffler. Just taking more measurements now.

 

[zags]

My 2 cents......I have been welding since I was 16 (I'm much older now) and I've found it's largely practice, patience, preparation and education. If you understand some basic metallurgy, what is really happening during the welding process, and which processes work best in specific applications - you'll do fine. The aluminized coating on exhaust tubing can be a bit of a challenge for a novice if you are NOT using a wire feed process with a shielding gas.

I have similar experience as and agree with reddingcruiser. My first thought was "If you have to ask......." Be sure to make some practice welds on some scrap tubing first. Remember that you need to constantly adjust your torch angle while welding around round tube, especially when you are all twisted around upside down, welding blind on the top of the pipe!

 

[thetoyotaman]

Thanks for all of the info. I learn a lot on this forum. I went to O'reillys today and bought the Thrush because I wanted the longer length and a 90 degree elbow. I was shocked when they told me it was on sale for $16.99. I then went and bought some 3/8" steel rod that I plan on trying to make a rear hanger out of.

 

[antFJ]

Hey thetoyotaman, here are the pics you asked for of the setup I did. The trickiest part for me was, due to the size of the muffler getting it positioned just right so nothing would hit while also keeping it as high as possible for ground clearance and axle clearance. The muffler was like $60 I think and the rest of the pieces (including the hangers) added up to like another $40-$50

View attachment 627590

Is that a steel brake line from the frame to the axle...????

 

[Bruzzi]

Is that a steel brake line from the frame to the axle...????

Haha!!! Looks like that don't it!...no that's just a lot of extra line the PO put on to hoop the pumpkin one side to the other.....just got the truck going down the road about 4 months ago and have been fixing/improving things as priority/necessity dictate....it's on the to-do list just lower down the list....building tire carriers and installing tops and seat are more gratifying then shortening some brake line....lol

 

[thetoyotaman]

I tacked the muffler up in the OEM flange and a floor jack to align tn all. When I get the floor fixed I will work on the rear support rod and finish it all. Very pleased with the results.