Well, I got the guts to try my hand at a hack pipe. Cost me all of $15 and 2hrs. I spaced on taking pics of the process, but basically it was cutting the muffler into 3 pieces. I kept the front and back stock, pulled out the center sleeve, and created my own internal pipe to connect the inlet and outlet.
I say create because there is no "pipe" connecting the two. I used 1/8" diamond mesh from Home Depot and rolled it around a wrapping paper tube to shape.I had my buddy tack it every few inches with a mig welder to keep it from unravelling. The mesh itself is about 6" wide and I overlapped it 3" to keep the shape. Then, I wrapped that tube with chopped fiberglass matting (Bondo brand if it matters). Wrapped that in another layer of mesh to keep it together (again, tacked together). Slid the inner "pipe" into the empty muffler over the exhaust port and packed the sides with more chopped matting. Welded the ends back on and BAM! Hack pipe that sounds pretty good! I'll post up a sound clip ASAP.
I say create because there is no "pipe" connecting the two. I used 1/8" diamond mesh from Home Depot and rolled it around a wrapping paper tube to shape.I had my buddy tack it every few inches with a mig welder to keep it from unravelling. The mesh itself is about 6" wide and I overlapped it 3" to keep the shape. Then, I wrapped that tube with chopped fiberglass matting (Bondo brand if it matters). Wrapped that in another layer of mesh to keep it together (again, tacked together). Slid the inner "pipe" into the empty muffler over the exhaust port and packed the sides with more chopped matting. Welded the ends back on and BAM! Hack pipe that sounds pretty good! I'll post up a sound clip ASAP.
