91 3pg exhaust options. HELP!!

Pig Punisher

Picked up a 91 marathon for free. The guy just wants it out of his way. The whole cart is in unknown condition but most everything seems to be there minus the carb and muffler. The engine, a 3pg, is not locked up. I can turn it by hand and seems to have some compression. I will be bolting on a carb next week to see if it will fire but I'm a little worried about firing her up with no exhaust. The header is still bolted to the engine just no muffler. I am thinking about building my own muffler or buying a dirt bike/ATV muffler to put in its place. How critical is scavenging to this engine? Can I get away with building my own muffler? I am a competent welder and fabricator but lack knowledge on a 2 stroke engine. I have searched, read, searched, scratched my head and threw up once already because of the price of a 3pg muffler. Please help!

BGW

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Pig Punisher

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Pig Punisher

I should say I'm looking into an exhaust pipe for a early 90's Polaris 250 trail boss. I would have to make some modifications for it to fit. Or building an aluminum muffler/expansion chamber myself. I really don't want to spend any more than necessary on this cart until I have verified that the engine is good and even then I'm not spending $800 plus for a muffler. I have had no luck locating a used muffler. I will post some engine pics when I am able to get back to the cart and snap a few.
Right now I'm not worried about how it sounds I just want to make sure it runs like it should and I don't do any harm to the engine.
Any insight on this engine is greatly appreciated.

Pig Punisher

One other thought. Maybe a bv-24 carb and modify a muffler from an 88 2pg.

kyerik

You could post a "3pg muffler wanted" ad in the for sale section of this website and see what happens.

If I were you, I'd try to find a round $20-30 auto muffler that was about right size/shape, weld up a side outlet and try to make that work. An auto parts store (autozone, advance, orileys etc.) might let you go back to the back and browse their stock to see what is close to the size yo need.

clr.R4tch3t

Factory muffler doesn't have any type of expansion chamber, and my rough estimates show a 125cc dirt scooter expansion​pipe has more accurate sizing for the engine displacement and rpm range. A 250cc pipe would be too big because of the lack of rpm's our little carts run. I also have a factory ezgo header pipe with a washer welded on the end (inside diameter about the size of my pinkey finger for some back pressure) as a test pipe (to delete the muffler and make install and mockup easy) and it works great for short tests/runs. I am currently putting a FMF Fatty gold pipe from a 96 Suzuki 125 on my 2pg motor with an 88 carb. Should be fun! Good luck!

Pig Punisher

Thanks for the replies. I will look into some 125 pipes. First Thing first is to get this little cart running and if the stock muffler didn't seem like unobtainium I wouldn't be stressing but you eased my mind quite a bit. This cart is gonna be an evening after work project for me as I work out of town and need something to do with my evenings to keep me out of trouble. I'll start another thread and be sure to take some pics as I go. Thanks again for the help. Lot of great knowledge on this forum