Building A Scooter Exhaust From Scrap Metal

When a part on a vehicle fails, oftentimes the response is to fit a new one fresh out the box. However, sometimes, whether by necessity or simply for the love of it, it’s possible to handcraft a solution instead. [Samodel] does just that when whipping up a new exhaust for his scooter out of scrap metal.

It’s a great example of classic backyard metalworking techniques. The flange is recreated using a cardboard template rubbed on the exhaust port, with the residual oil leaving a clear impression. Hard work with a grinder and drill get things started, with an insane amount of filing to finish the piece off nicely. A properly tuned pipe is then sketched out on the computer, and a paper template created. These templates are cut out of an old fridge to create the main muffler section.

There’s plenty of other hacks, too – from quick and dirty pipe bends to handy sheet forming techniques. It’s not the first time we’ve seen great metalworking with scrap material, either. Video after the break.

[Thanks to BrendaEM for the tip]

20 thoughts on “Building A Scooter Exhaust From Scrap Metal

      1. A large automotive oil filter probably does pretty well. Though I’d want it a foot or two in the air above the motor so you can’t fill it up with gas when you’re failing to start the motor. Just have this weird orange toadstool sticking up a foot from your mower LOL

    1. If you want an actual tuned pipe, you crunch the data for your actual motor with it’s other modifications, and custom build. If you want one that makes it look fast, you buy one off eBay.

        1. I have heard it said that the nasty cheapie honda eBay headers actually do better on not far off stock motors because the crush bends keep the volume/CSA down.

  1. All of a sudden I don’t feel so bad about the super-quiet muffler I bodged together for a generator (that’s still intact after many years).

    Bonus points for fearless riding on “Bigstone” tires.

  2. There is an entire other internet for the russian speakers.
    Part of the reason i’m looking foward to learn it.
    I’m also glad i speak english and spanish, you can find new perspectives on DIY and problem solving.

    Also, i remember seeying a machinist using the cardboard/oil technique to copy a quick change tool post from a lathe. It worked quite well!

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