Abstract: A stamp formed muffler comprising a pair of internal plates and a pair of external shells is provided. The internal plates are stamp formed to define first and second spaced apart arrays of tubes and a single intermediate tube therebetween. Tubes in one array may have perforations or apertures to permit expansion of exhaust gases, while the other array may define at least one tuning tube. The tubes are disposed on the internal plates such that at at least one location thereon a straight line extending entirely across said internal plates will intersect only the one intermediate tube. The external shells are stamp formed to define a plurality of chambers which cooperate with the tubes in the internal plates. The chambers are separated from one another by a crease disposed to align with the intermediate tube. The crease is characterized by a single outwardly convex portion to engage the single bulb. As a result, the crease is not provided with recesses that conceivably could retain corrosive materials.

Abstract: A process and an apparatus for forming an air gap pipe are provided. Inner and outer pipes are bent or deformed into comparable configurations such that the inner pipe can be mounted within the outer pipe. The outer pipe then is split longitudinally by a preprogrammed cutting apparatus. The cutting of the outer pipe terminates just short of the complete longitudinal length of the pipe to facilitate rematching later in the process. The cutter includes a follower to trace the actual configuration of the pipe and thereby to offset differences from one pipe to the next. An array of clamps are provided to align the outer pipe halves relative to one another and to facilitate the reattachment.

Abstract: A process is provided for manufacturing an exhaust manifold. The manifold comprises at least one stamp formed inlet flange, a stamp formed sheet metal inner shell and a stamp formed sheet metal outer shell. The inner shell and outer shell are configured to define an exhaust chamber therebetween. Each inlet flange is stamp formed to define at least one exhaust port extending entirely therethrough, with each exhaust port including a stamp formed projection extending continuously thereabout from one surface of the inlet flange. The inner shell is stamp formed to define an inlet aperture for each exhaust port. The inner shell is projection welded to the inlet flange such that the projections stamp formed therein define the weldments. The outer shell then is welded to the inner shell to define the exhaust chamber of the manifold. An outlet tube may be secured to an outlet aperture of the outer shell.

Abstract: A muffler is provided with a pair of internal plates stamp formed to define an array of tubes therebetween. An external shell, which may be stamp formed, surrounds and encloses at least selected portions of the internal plates. The array of tubes stamp formed in the internal plates includes at least two tuning tubes. One tuning tube terminates at a tuning aperture in one of the two internal plates, while the other tuning tube terminates at an aperture stamp formed in the other of the two internal plates. Thus, one tuning tube will communicate with a low frequency resonating chamber on one side of the pair of internal plates, while the other tuning tube will communicate with a low frequency resonating chamber on the opposite side of the assembled internal plates.

Abstract: An exhaust muffler is provided. The muffler may be formed from a pair of internal plates that are secured in registration with one another and are formed to define an array of tubes through which the exhaust gages may travel. Selected portions of the tubes in the internal plates may be formed to include perforations. The muffler may further include at least one external shell formed to define at least one chamber which may at least partly surround the perforations in the internal plates. At least one inlet or outlet may lie on the seam between the formed plate members. However, at least one inlet or outlet may also be provided through a portion of the muffler spaced from the seams. The inlet and/or the outlet may be angularly aligned to the longitudinal axis of the muffler and may further be angularly aligned to one another.

Abstract: A muffler is provided including a pair of internal plates formed to define an array of tubes. At least one external shell is formed to define at least one chamber which will surround and enclose a selected portion of the array of tubes. Selected portions of certain tubes will be formed to include perforations. Portions of certain tubes will further undergo cross-sectional changes to control the flow of exhaust gases through the muffler. Certain channels between adjacent chambers of the external shell will be disposed to extend substantially continuously from peripheral portions of the adjacent chambers formed in the external shell. In certain embodiments, a controlled communication is provided between a low frequency resonating chamber and an adjacent expansion chamber. In other embodiments, additional formed layers are provided to enhance either heat or noise insulation.

Abstract: A bending apparatus is provided for rectangular tubes. The apparatus comprises a bending die, a wiper die, a clamp die, a pressure die and a mandrel. The clamp die and pressure die are provided with tongues which are engageable in corresponding grooves in the bending and wiper dies. The tongues and the clamping and pressure surfaces of the respective dies are dimensioned to enable the rectangular tube to be bent about either of its two axes by placing the tube on either of the opposed sides of the respective tongues. The tongue of the pressure die is movable to facilitate the tangential advancement of the pressure die under the action of a booster for urging the tubing into the bend. The mandrel includes a plurality of movable blocks. A plurality of springs interconnect the blocks to facilitate alignment. The blocks are mounted to a replaceable head which can be removed and replaced when worn. The mandrel includes channels for lubrication.

Abstract: A muffler is provided with a pair of stamp formed internal plates and a pair of stamp formed external shells. The internal plates define inlet and outlet tubes at least portions of which are provided with arrays of perforations or louvers. One or more tuning tubes may be stamp formed in the internal plates and one or more low frequency resonator chambers may be stamp formed from portions of either the internal plates or the external shells. The external shells may further be configured to define high frequency tuning chambers of a selected size and shape.

Abstract: A precision bending apparatus is provided for precisely bending tubes. The precision bending apparatus includes a preprogrammed bender for placing a selected sequence of bends in the tube. The apparatus further includes a position sensing means for sensing the precise position of locations on the bent portion of the tube. A control means is in communication with both the position sensing means and the bender, and is operative to alter the program of the bender based on data sensed by the position sensing means.

Abstract: A process and an apparatus for forming an air gap pipe are provided. Inner and outer pipes are bent or deformed into comparable configurations such that the inner pipe can be mounted within the outer pipe. The outer pipe then is split longitudinally by a preprogrammed cutting apparatus. The cutting of the outer pipe terminates just short of the complete longitudinal length of the pipe to facilitate rematching later in the process. The cutter includes a follower to trace the actual configuration of the pipe and thereby to offset differences from one pipe to the next. An array of clamps are provided to align the outer pipe halves relative to one another and to facilitate the reattachment.

Abstract: A muffler is provided with a pair of stamp formed internal plates and a pair of stamp formed external shells. The internal plates define inlet and outlet tubes at least portions of which are provided with arrays of perforations or louvers. One or more tuning tubes may be stamp formed in the internal plates and one or more low frequency resonator chambers may be stamp formed from portions of either the internal plates or the external shells. The external shells may further be configured to define high frequency tuning chambers of a selected size and shape.

Abstract: A process and an apparatus for forming an air gap pipe are provided. Inner and outer pipes are bent or deformed into comparable configurations such that the inner pipe can be mounted within the outer pipe. The outer pipe then is split longitudinally by a preprogrammed cutting apparatus. The cutting of the outer pipe terminates just short of the complete longitudinal length of the pipe to facilitate rematching later in the process. The cutter includes a follower to trace the actual configuration of the pipe and thereby to offset differences from one pipe to the next. An array of clamps are provided to align the outer pipe halves relative to one another and to facilitate the reattachment.

Abstract: A method is provided for manufacturing a heat shield for an exhaust system component. The exhaust system component preferably is of tubular nonlinear configuration. The heat shield is formed from a larger pipe having an internal diameter greater than the outer diameter of the exhaust system component. Appropriately dimensioned inwardly directed supports are formed in the larger pipe. The larger pipe then is bent into a nonlinear configuration substantially identical to the configuration of the exhaust system component. The outer pipe then is cut longitudinally in half along its entire length to define a unitary nonlinear heat shield which can be mounted to the exhaust system component. A portion of the remaining half of the larger pipe can be reattached to the heat shield to provide an air gap pipe along a portion of the length of the exhaust system component.

Abstract: A universal mounting bracket assembly is provided to mount an exhaust system to a vehicle. The universal mounting bracket assembly includes a clamp mountable to a pipe of the exhaust system. The clamp is adjustably mountable to an elongated support plate. A formed support rod is mountable to the vehicle and adjustably attachable to the elongated support plate. The formed support rod may be mounted to the vehicle through a rubber insulator.

Abstract: A tool for urging an enlarged head of a vehicular exhaust system mounting stud from an insulator. The tool includes a driver having a driving shaft for contacting the enlarged head and applying forces thereto. The tool also includes a support pivotally mounted to the driver. The support includes a pair of spaced apart arms. The arms define first and second supporting surfaces. The supporting surfaces are angularly aligned relative to one another such that the first and second support surfaces can be used sequentially for urging the enlarged head completely through the insulator.