Building and tuning, Bud Bottle Mufflers. (Full Version)

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altavillan -> Building and tuning, Bud Bottle Mufflers. (4/17/2008 9:20:17 PM)

This post is to show how to build the Bud Beer Bottle Mufflers, and for sharing tips on tuning and mounting ideas. Feel free to add your own designs or ask questions if you like what you see and want to try building your own.



altavillan -> RE: Building and tuning, Bud Bottle Mufflers. (4/17/2008 9:30:44 PM)

Tony, The header lengths for the 115 in the Katana is 6 9/16" from the engine exhaust flange to the coupler, measured on centerline. From the coupler to the lip of the Bottle top is 2 1/8" for an overall length of 8 11/16".
The stingers do not seem to add nor detract power. But are very helpfull for reducing noise and ejecting exhaust oils away from the plane. The headers were adjusted to length for using KS86 cannisters. I can't get the Bud Bottle mufflers any farther forward or they would be 2 1/8" closer. I'll eventualy get around to making a new set of pipes with the bottle farther forward to more closely match the way the KS canns. fit.



tonyc -> RE: Building and tuning, Bud Bottle Mufflers. (4/17/2008 10:34:49 PM)

altavillan, thanks for starting this. I found this picture on the Giants site. We do not know who's it is because the poster of the picture said it was not his. But it gives a view of the BME and a bottle muffler. Perhaps someone will reconize this picture and tell us something about it.



fritzdecat -> RE: Building and tuning, Bud Bottle Mufflers. (4/18/2008 2:07:34 AM)

time to drink some Iron City...New Iron City Bottles



mmattockx -> RE: Building and tuning, Bud Bottle Mufflers. (4/18/2008 7:09:19 PM)

Since we don't get the aluminum bottles up here, does anybody want to drink a case and then send me the empties?? I brought a couple of empties back from Vegas 18 months ago, but I will need more that that eventually...[:D]

PM me if you are serious about shipping some, we can make arrangements off line.

Thanks,
Mark



tonyc -> RE: Building and tuning, Bud Bottle Mufflers. (4/23/2008 4:20:56 PM)

What diameter tube did you use for the 115? Did you find something that would fit the nick of the bottle or did you widen the nick?

I did find the Budweiser bottle's. So far I have $6 invested for 4 bottle's. I think this means I need a second twin to use up the extra bottles. Must not be wasteful.



sscherin -> RE: Building and tuning, Bud Bottle Mufflers. (4/23/2008 4:40:18 PM)

All the stores around here stoped stocking the AU bottles..
I might have to check out the Specialty stores.



coronabob -> RE: Building and tuning, Bud Bottle Mufflers. (4/23/2008 5:48:41 PM)

Where can I get a 1" Flairing punch?



altavillan -> RE: Building and tuning, Bud Bottle Mufflers. (4/23/2008 6:57:04 PM)

Get a long 1" bolt or rod and grind it round. A piece of hardwood dowel should work also for flairing a hole out the back. You will still need something hard/round and close to 1" to be able to hammer the neck out to 1" ID.
Tony almost all exhaust pipes use 1" O.D. material. 50cc and up per cylinder.
No reason why the neck couldn't be cut off where a 1" OD pipe would fit so as not to have to reshape the bottle top.



Nogyro -> RE: Building and tuning, Bud Bottle Mufflers. (4/24/2008 1:55:16 AM)

I know this is for gassers, but I'm using one on my OS AX 120. [:D] Mac's header cut to 6" overall length, 3/8 hole drilled in bottom of bottle. That's it..... I may have to give it a try on my next gas project. [sm=thumbs_up.gif]



sscherin -> RE: Building and tuning, Bud Bottle Mufflers. (4/24/2008 6:38:05 AM)

I have an el-cheepo tip for a flaring punch..

I've done it before by working my way up through a series of progressively larger sockets on an extension.

the dowel idea would also work fine.. Use a good hardwood dowel.



tonyc -> RE: Building and tuning, Bud Bottle Mufflers. (4/24/2008 2:31:29 PM)

Is the flaring tool expand the nick of the bottle to fit the tube or is it just for the outlet in the back of the bottle?



altavillan -> RE: Building and tuning, Bud Bottle Mufflers. (4/24/2008 3:23:21 PM)

I put the flaring tool in a vice and start working the neck on it by rocking back and forth and using a hammer to expand and flatten the neck until it slides through. Then punch out the back.



altavillan -> RE: Building and tuning, Bud Bottle Mufflers. (4/24/2008 8:55:10 PM)

Just be careful some of those older folks swing a mean cane. Save your dignity here's 4 mufflers[:D]http://www.amazon.com/Coleman-C015B799-Rambler-Stool-Charcoal/dp/B000EGZ3XE/ref=sr_1_1?ie=UTF8&s=sporting-goods&qid=1209066823&sr=1-1 .. Or google Coleman cot/stool.



altavillan -> RE: Building and tuning, Bud Bottle Mufflers. (5/5/2008 4:38:36 AM)

With a few weeks of testing this muffler I can say it gives equal or greater performance to the store bought, top of the line cannister mufflers they replaced. Both in sound and rpm. As far as weight goes they are 6+ oz per pair lighter. Not bad for about $10 apiece.



karolh -> RE: Building and tuning, Bud Bottle Mufflers. (5/5/2008 1:13:44 PM)

I am interested in trying my hand at making a similar can type muffler for my little league 23cc engine and would like to know what size volume can would be a good starting choice.

Karol.



altavillan -> RE: Building and tuning, Bud Bottle Mufflers. (5/5/2008 2:33:50 PM)

Acording to Pat. 5 to 1 is a good starting point. So if you have a 2 cubic inch engine you need a 10 cubic inch cann. Header length is much more important than cann size.



buck1856 -> RE: Building and tuning, Bud Bottle Mufflers. (5/16/2008 4:18:44 AM)

The center pipe with the holes in it.Do you have a plug in the middle.Also,if you do,is the idea to get the exhaust to go out the first set of holes,then bypass the spacer and reenter the rear set of holes like a baffle system.What are the styrofoam spacers for and where do they go.



altavillan -> RE: Building and tuning, Bud Bottle Mufflers. (5/16/2008 4:38:14 AM)

Yes the plug makes the exhaust travel out then back in through the holes. The Foam just causes a gap between which silicone is squeesed into till full. Lots of holes in the center to hold the plug in place + one larger one to use as a fill hole for squeesing in the silicone. The foam burns off first flight leaving the baffle.



tonyc -> RE: Building and tuning, Bud Bottle Mufflers. (5/16/2008 7:44:09 PM)

UPS just delivered my Coleman Rambler Stool. The aluminum legs are an exact fit for the flex header on the BME 115. Thanks for the tip on this stool. It only cost me $20 includint the shipping. This will make 4 mufflers and two prop sleeves. What a bargin.



buck1856 -> RE: Building and tuning, Bud Bottle Mufflers. (5/17/2008 4:28:03 AM)

Thanks altavillan.I was thinking about making mine so the larger[bottom end] is the intake,1" diameter in the center.Entered in about 2 inches.Then put a 1/2 inch exit pipe out the smaller end[top].I believe this would give it more of an expansion chamber with more back pressure.Do you think this would be more powerful,but a little noisier.Maybe better throttle response,or would it make the needles more sensitive.I have an article from M.A.N.,March 1994.It tells how to make a mousse can muffler power producing and its made like the way im going to make mine.So,i guess ill be the first to try maybe.Anyway,heres a pic of my roof rack[aluminum] from my conversion van.The OD is the same size as the ID of the headers i just bought here from rcu.3W.Im going to put them on my GT80.Nice brackets also,one is straight and the other is angled.My wife already asked me where the parts cam from and i told here they werent needed anymore and where just laying around now.[im getting rid of the van].



altavillan -> RE: Building and tuning, Bud Bottle Mufflers. (5/17/2008 6:14:02 AM)

I tried a set on the Kat with the 115 that had 1" outlets but it slobbered up the bottom of the plane so bad after just a couple flights, I real quickly put 1/2 inch stingers on. I think the stingers might help to produce some of the good tendencies these canns have. Mine do more power than the store bought cans they replaced. And very closely equal or excede the tuned mufflers I have also. And in both cases reduce weight significantly.
But sheesh man, cutting up the van?[:D]



buck1856 -> RE: Building and tuning, Bud Bottle Mufflers. (5/17/2008 6:44:58 AM)

Thats good to know.Im going to do mine opposite from yours and put the neck part to the rear.This is what the article in MAN shows and all of there tests where really good and produced more power.Now these where for the fun fly glow engines.As to the van,its up for sale as it needs a new steering colum[ign system],and a couple other things.Basiclly selling the engine and trans.The last time i drove it i got 14MPG on the highway.And its even fuel injected.Heck,there might be other parts i could use.



buck1856 -> RE: Building and tuning, Bud Bottle Mufflers. (5/18/2008 6:07:49 AM)

Heres a few updates and pics.I found a nice tool for expanding the aluminum.It starts out at about 5/8,then its 3/4 for about 1 inch,then the flare ends up to 1 inch exact for the full length of the pipe.Didnt get it from my van but got it from my boys bicycle parts.[its the seat stem].Just cut off the lip of the bottle so it fit snug and after drilling out the bottom to 11/16ths and drove it through.You can see in the pic that the 1 inch tube is tite at both ends.The other pipe is one i made the way the M.A.N. article shows to build it.Says it has plenty of backpressure and because its tapered at the back it produces a decent wave.Its made out of a mousse can and the large end is JB welded in.The front pipe is in 1-2 inches and the back one is flush with the inside of bottle.The other piece is the seat stem.I plan on building mine the way altavillan did with the holes and plug with a turned down 1/2 inch stinger or whatever i can find thats smaller.The other set im going to make are going to be the tuned pipe with just a large inlet and a small outlet,itll look like the top mousecan one.



tonyc -> RE: Building and tuning, Bud Bottle Mufflers. (5/19/2008 2:55:38 PM)

Vibration mounting the muffler.

I found something that I am going to try and see if it works on my mufflers. While shopping with my wife we went into a kitchen gadgets store. There I found bright blue silicone muffin baking pans. These were the miniature muffins size and the pans came two to a set with 6 muffin cups in each pan. The pans are good to 450 degrees. I should be able to cut out the muffin cups and mount them into a balsa or ply frame and pass the muffler exhaust leg through the support. It would be a very soft mount and allow for a lot of vibration with none being transferred to the frame. If there is any interest I will post a picture of what it looks like when I get it built.



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