Muffler adapting

tew45 · 06-17-2016, 11:29 PM

I bought a new muffler for my 1976 D model. It is a later model with the inlet pipe on the end. The pipe is 1 1/4 inch and the older one is 1/1/2 in pipe. I have to modify the mount bracket some and the pipe I will have to fabricate. Does anyone have a used pipe or a photo of one installed on a cart. Any Ideas will be appreciated.

johnny reb · 06-18-2016, 07:00 PM

i have carts with 2 types of mufflers one is a simple type like the picture (note i cut it open and rewelded the baffles) the other has a layer of asbestos? in between the 2 steel layers. im not really sure what your muffler looks like but you should be able to rig something. when i get time i plan on going to my local small engine shop and finding a source for exhaust and carb gaskets

tew45 · 06-18-2016, 08:31 PM

The muffler on my 1976 looks like that one and the 1974 also used one like that but it was garbage which I will repair when there is time. I bought a like new old stock with the inlet on the battery or gas tank side. It will have to be modified slightly and a long exhaust pipe used. I would like a photo of the long pipe muffler installed so I can use the 1 1/4 bent tub to fabricate a new pipe.

johnny reb · 06-28-2016, 06:59 PM

sorry ive been out with shoulder surgery. the longer one discharges to the right of the engine about inline with the carb. whereas the other discharges about the crankshaft. the inlets are in the same location. i will raise a body and get a pic tomorrow.

johnny reb · 06-28-2016, 07:11 PM

a diagram i made a while back

johnny reb · 06-29-2016, 10:35 AM

this is a 1973 model

tew45 · 06-29-2016, 11:19 PM

Thanks folks I may be able to use the inside diagram but I did not make myself clear. I might be able to modify the inlet to the muffler and make it usable. The muffler I have is a 1983 muffler. It has the inlet on the right end and it is 11/4 pipe where the older ones have a 1 1/2 inch inlet. the exhaust pipe runs from the cylinder, across the length of the muffler and a 90 degree turn and into the end of the muffler. I expect to buy some prebent tubing to make a new exhaust pipe. I was hoping to get a photo of a '83 or other cart that used that muffler. I hate to not use it since it is like new. I loved the photos you sent since I can compare them to my other cart and make sure it firs properly. I have a 1974 D4 and a 1976 D model. Thanks again for the photos.

73eldo · 06-30-2016, 08:20 AM

My 82

raydhd · 06-30-2016, 08:50 AM

That is the type of muffler that was on the 1982 D model.Some sites sell a used unit for $260 +.So I bought the earlier unit for $119 and adapted it.If I understand you correctly you want to do the opposite.IMHO you should sell that rare muffler to some purist and buy the muffler that fits your cart and have plenty of cash to boot.

tew45 · 06-30-2016, 02:56 PM

Thank you 73eldo! That was what I was looking for. I will order the 1 1/4 tubing for the exhaust pipe fabrication. The bent pipe comes in one piece with a 90 degree and a 180 bend. My 76 exhaust is a 1 1/2 inch which will be easy to reduce while making a final bend to the engine. Thanks to all of you for helping when I get in trouble.

06-17-2016, 11:29 PM	#1
tew45 Gone Wild Join Date: Aug 2007 Location: North Texas Posts: 2,312	Muffler adapting I bought a new muffler for my 1976 D model. It is a later model with the inlet pipe on the end. The pipe is 1 1/4 inch and the older one is 1/1/2 in pipe. I have to modify the mount bracket some and the pipe I will have to fabricate. Does anyone have a used pipe or a photo of one installed on a cart. Any Ideas will be appreciated.

06-18-2016, 08:31 PM	#3
tew45 Gone Wild Join Date: Aug 2007 Location: North Texas Posts: 2,312	Re: Muffler adapting The muffler on my 1976 looks like that one and the 1974 also used one like that but it was garbage which I will repair when there is time. I bought a like new old stock with the inlet on the battery or gas tank side. It will have to be modified slightly and a long exhaust pipe used. I would like a photo of the long pipe muffler installed so I can use the 1 1/4 bent tub to fabricate a new pipe.

06-28-2016, 06:59 PM	#4
johnny reb Gone Wild Join Date: Aug 2015 Location: Albertville,Al Posts: 344	Re: Muffler adapting sorry ive been out with shoulder surgery. the longer one discharges to the right of the engine about inline with the carb. whereas the other discharges about the crankshaft. the inlets are in the same location. i will raise a body and get a pic tomorrow. Last edited by johnny reb; 06-28-2016 at 07:05 PM.. Reason: add pic

06-29-2016, 11:19 PM	#7
tew45 Gone Wild Join Date: Aug 2007 Location: North Texas Posts: 2,312	Re: Muffler adapting Thanks folks I may be able to use the inside diagram but I did not make myself clear. I might be able to modify the inlet to the muffler and make it usable. The muffler I have is a 1983 muffler. It has the inlet on the right end and it is 11/4 pipe where the older ones have a 1 1/2 inch inlet. the exhaust pipe runs from the cylinder, across the length of the muffler and a 90 degree turn and into the end of the muffler. I expect to buy some prebent tubing to make a new exhaust pipe. I was hoping to get a photo of a '83 or other cart that used that muffler. I hate to not use it since it is like new. I loved the photos you sent since I can compare them to my other cart and make sure it firs properly. I have a 1974 D4 and a 1976 D model. Thanks again for the photos.

06-30-2016, 08:20 AM	#8
73eldo Gone Wild Join Date: Jul 2014 Location: St. Paul Minneapolis MN USA Posts: 522	Re: Muffler adapting My 82

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06-30-2016, 08:50 AM	#9
raydhd VC 460 CLONE GONE WILD Join Date: Oct 2014 Location: Ray BY The Bay NJ Posts: 10,646	Re: Muffler adapting That is the type of muffler that was on the 1982 D model.Some sites sell a used unit for $260 +.So I bought the earlier unit for $119 and adapted it.If I understand you correctly you want to do the opposite.IMHO you should sell that rare muffler to some purist and buy the muffler that fits your cart and have plenty of cash to boot.

06-30-2016, 02:56 PM	#10
tew45 Gone Wild Join Date: Aug 2007 Location: North Texas Posts: 2,312	Re: Muffler adapting Thank you 73eldo! That was what I was looking for. I will order the 1 1/4 tubing for the exhaust pipe fabrication. The bent pipe comes in one piece with a 90 degree and a 180 bend. My 76 exhaust is a 1 1/2 inch which will be easy to reduce while making a final bend to the engine. Thanks to all of you for helping when I get in trouble.

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