Thanks, I have made a few motorcycle mufflers, just scaled it up in size.
I was going to drill out an aluminum tube, then wised up when I happened across some perforated aluminum sheet in the scrap bin. I used a slip roll to roll it to 3.5" ID, fused the ends of the sheet together and tacked it to the tubing for inlet and outlet. Unfortunately I did not take too many "in-progress" pics. I thought about making a box style case, but rolling the round case was easier. Do you have any insulation in your cases?
I am just running a stainless collector extensions as a means to adapt the 3 bolt flange at the collector to the aluminum tubing. I will also house my crankcase evac and O2 sensors in the extensions. I am leaning towards a slip fit to join the alum with the SS, then will go into aluminum tube, aluminum x-pipe, and the aluminum mufflers in the factory muffler recess area with dumps before the axle. Mocking this stuff laying on my back has been enjoyable...
