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Old 10-06-2014, 09:50 PM   #1
markups09
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Default 87 marathon 2pg

Alright guys I finally lost compression. I was getting blow by and I don't think it was the rings. I'm not 100% sure but I think the piston was slapping a little and got the cylinder out of round. I ordered a new cylinder piston rings the whole 9. I had a brand new carb so I threw it in the new parts pile. I'm waiting for another base gasket to get to me should be here tomorrow. When I get it I'm taking my head to a machinist friend and having the head milled .020 + the thickness of the base gasket. I'm going to run 2 base gaskets. I wanted some extra power and didn't have the ability to make a new reed cage setup like Morgan so I decide to do the only other thing I was capable of at the moment. I cut both ends off my muffler and ripped all of the rotten guts out of it. Now not sure how many of you guys opened one of these up but they are severely restrictive as you would most likely imagine. The inlet was something like 11/2"-13/4 " not sure at this moment I'm relaxing (glug, glug) but the outlet is only 3/4" and there's a whole bunch of junk in between. So I did what any backyard mechanic would do I grabbed some junk I had laying around and made it better. I had an old metal chair that was a complete failure as a chair so it was reclaimed to become something useful for once in its life. I cut a straight section of tube off of it, it was a little too small to fit tight in the inside of the muffler inlet. So I new the OD of my new tube was 1 1/4 OD so I cut a piece of oak and drilled a 1 1/4hole in it, then cut it in half thru the hole. I used some c clamps and used it to shrink the pipe to my size it work well only got 1 little wrinkle but nothing a heavy bead of weld couldn't fix. So before I welded the new center tube i drilled a literal **** ton of holes in it, basically rows of wholes from after the weld location out to the point just before it exited the can. I filled it and packed the whole can tight with insulation. I drilled the outlet hole of the exhaust can out with a hole saw and let my new tube hang outside the can then welded it all tight. ( which was a pain on that old muffler, I made more holes than I could fill for awhile before getting my heat right ) here's some pics
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Old 10-06-2014, 09:52 PM   #2
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Default Re: 87 marathon 2pg

Sorry for the grammar my iPad thinks it smarter than me
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Old 10-06-2014, 09:56 PM   #3
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Default Re: 87 marathon 2pg

Muffler
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Old 10-06-2014, 09:58 PM   #4
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Default Re: 87 marathon 2pg

Hhhhh
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Old 10-06-2014, 10:00 PM   #5
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Default Re: 87 marathon 2pg

You can see some of the original muffler innards in the backround
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Old 10-06-2014, 10:04 PM   #6
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Default Re: 87 marathon 2pg

Why do I have to type here
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Old 10-07-2014, 11:54 PM   #7
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Default Re: 87 marathon 2pg

That's really wild..... Seems I remember a few years back, someone on here talking about the mufflers needing a certain amount of restriction for the engine to operate properly but, if what you are doing works, then document it well and it may help out another member!
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Old 10-08-2014, 12:31 PM   #8
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Default Re: 87 marathon 2pg

Exhaust a a big deal for 2 strokes, I had a buggy help me figure out what would be the best method. He is a 2 stroke racing freak and he got me to realize the importance of packing the insulation as tight as humanly possible. That being said if it doesn't work well I have a backup plan, I have a complete banshee exhaust since its a twin I only need 1 side of it but I have the expansion chambers and silencers so il make that work somehow. All that said I just hope mine works the first but I think we've all said that once or twice before just to have it not work. So here's to hoping lol
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Old 10-10-2014, 10:03 AM   #9
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Default Re: 87 marathon 2pg

Good deal with that muffler repair/build. darn mufflers cost as much as a total new exhaust on an f250 superduty. My 3pg muffler ever fails I had planned on doing what you are doing. Take it down and copy the internal parts in my shop. Have heard of a guy also that used a garden tractor muffler he located that welded up to his pipe pretty easey and that worked also he said for about $25 if my memory is correct.
Keep us posted on your results.
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Old 10-10-2014, 04:46 PM   #10
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Default Re: 87 marathon 2pg

also 2 stroke yes, i think the 4 stroke needs the backpressure more. i think.......
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