The muffler shop wanted $100 to do this for me. I said screw that. I'll just do it myself. The FMF quiet insert I ordered was a 1 3/8 inch device. It does a decent job of knocking the edge off the sound. But I wanted a little more. So I went to Home Depot and bought some 28 guage sheet metal and a 1 1/4 inch wooden dowel. I wrapped the metal around the dowel and trimmed it with snips. To wrap it, I wore gloves and forced the sheet over the dowel, slowly turning as I held the metal against the dowel. It took considerable effort. A machine would have made this much easier. One end was the same diameter as the FMF insert. The other end I pressed on itself with my vice, narrowing it to 1 inch, making a taper. I tack welded the affair together with my cheap-o Chicago Electric 90 amp 120 volt flux core wire welder. Did some practice welds first. Once the pieces were welded, I shoved the thing into the end of the pipe. Nice. Took just a little more of the edge off the sound. Sounds perfect to my ears now. The construction is very ghetto. I don't have the proper tools to do a great looking job, but this just goes to show that with even the basic tools, a hammer, and some muscle, you can fashion stuff that will work just fine. Nobody's ever going to see the inside of this thing anyway. The whole project cost $12. Any questions? Fire away. I'll do my best to answer them. Yup, it's ghetto. But it works great! Below: Ready to weld. The extension still needs to be tapered and cut shorter. Below: Tack welded and cut to length Below: Tapered down to one inch diameter. Sounds good. Looks like crap.
