BrandonF260Rem
New member
I've had a little go kart project going on for a while LINK and I've got all the frame work like I want it so now its time to tweak the engine and see what kinda of power we can get out of it.
This thread is about building up the exhaust to allow some free flow of exhaust. Everyone says the stock muffler is really restrictive.
I've had some one inch stainless tubing with a few 90 degree bends in it for years I've been hanging on to.
I started out with buying a exhaust flange from Affordable Go Karts, I bought the CNC machined flange and was really impressed with the quality of it. The transition from a D shaped port to a 1 inch tube was impressive.
I installed the flange and took a short piece with a 90 in it on the flange. I took it to the belt sander and cut it back with about 9 degree angle, to the back, so the tube would come out perpendicular to the head.
Next was the down pipe section which was pretty easy. All I did there was belt sand the two ends to a flush fit end. This bend I rotated down to go into the muffler section.
The next section was kind of tricky. My muffler selection was a stainless steel liquid displacer, aka a float, out of a pressure vessel I found in scrap. This little pill shaped chamber was pretty thin. I took it up to a friends machine shop and spun it out on the lathe and cut a 1 inch hole in the top for the tubing to go into. We put it on a milling machine and stepped up from 1/2 to 1" bits and cut the hole in the side for the exhaust tip. Took it all back home and test fit.
Next it was time to TIG weld it all up.
Here is the Final Product. It sounds good, and looks even cooler. It does have some back popping when you let off the throttle but I need to do some more carb tuning on it.
So there is the stainless exhaust project in a nut shell. A little cutting, grinding, fitting, and welding can build anything you have the Imagination for.
This thread is about building up the exhaust to allow some free flow of exhaust. Everyone says the stock muffler is really restrictive.
I've had some one inch stainless tubing with a few 90 degree bends in it for years I've been hanging on to.
I started out with buying a exhaust flange from Affordable Go Karts, I bought the CNC machined flange and was really impressed with the quality of it. The transition from a D shaped port to a 1 inch tube was impressive.
I installed the flange and took a short piece with a 90 in it on the flange. I took it to the belt sander and cut it back with about 9 degree angle, to the back, so the tube would come out perpendicular to the head.
Next was the down pipe section which was pretty easy. All I did there was belt sand the two ends to a flush fit end. This bend I rotated down to go into the muffler section.
The next section was kind of tricky. My muffler selection was a stainless steel liquid displacer, aka a float, out of a pressure vessel I found in scrap. This little pill shaped chamber was pretty thin. I took it up to a friends machine shop and spun it out on the lathe and cut a 1 inch hole in the top for the tubing to go into. We put it on a milling machine and stepped up from 1/2 to 1" bits and cut the hole in the side for the exhaust tip. Took it all back home and test fit.
Next it was time to TIG weld it all up.
Here is the Final Product. It sounds good, and looks even cooler. It does have some back popping when you let off the throttle but I need to do some more carb tuning on it.
So there is the stainless exhaust project in a nut shell. A little cutting, grinding, fitting, and welding can build anything you have the Imagination for.
