Abstract: An air gap pipe and a method for forming the same are provided. The air gap pipe includes a non-linear outer pipe and an inner pipe of identical configuration disposed concentrically within the outer pipe. The inner pipe is supported by resilient dimples in the outer pipe. The outer pipe is placed in a condition for receiving the inner pipe by longitudinally cutting the outer pipe in half with a pre-programmed plasma arc or laser cutting apparatus. The two halves of the outer pipe are secured together to provide vents, if necessary, for selective dissipation of heat.

Abstract: An air gap pipe and a method for forming the same are provided. The air gap pipe includes a non-linear outer pipe and an inner pipe of identical configuration disposed concentrically within the outer pipe. The inner pipe is supported by resilient dimples in the outer pipe. The outer pipe is placed in a condition for receiving the inner pipe by longitudinally cutting the outer pipe in half with a pre-programmed plasma arc or laser cutting apparatus. The two halves of the outer pipe are secured together to provide vents, if necessary, for selective dissipation of heat.

Abstract: Double walled tubing, a method and apparatus for producing the same are disclosed. First and second metal tubes of substantially identical diameters are selected. One end of the second tube is expanded, and the first tube is pushed into the second tube. By mounting the first tube on a mandrel having a mandrel ball with an outer diameter which approximates the inner diameter of the first tube, any creases in the first tube caused by the insertion will be removed by the mandrel ball upon withdrawing the mandrel from the first tube.

Abstract: A technique for securing a tube to a flange includes the steps of inserting the end of the tube into an aperture provided on the flange from the first side of the flange such that a portion of the tube extends at least to, and preferably beyond the second side of the flange opposite the first side. A ceramic plug is optionally inserted into the end of the tube to prevent weld spatter and tube burn-through. The tube is then welded to the flange about the circumference of the tube from the second side of the flange, and that portion of the tube which extends beyond the second side of the flange is removed by grinding to produce the finished product.

Abstract: A hybrid exhaust manifold is provided for use with a vehicular engine. The manifold includes an inlet flange formed from a metal plate to be mounted against the engine cylinder head. The inlet flange includes exhaust ports which align with the exhaust ports of the engine cylinder head. Inner and outer stamped sheet metal shells are provided to mate with one another for forming an enclosed exhaust chamber. The inner shell includes inlet apertures which align respectively with the exhaust ports of the inlet flange. The outer shell includes an outlet aperture. An outlet tube is affixed to the outlet aperture of the outer shell, and an outlet flange is affixed to the end of the outlet tube opposite the outer shell to facilitate connection of the outlet tube to the exhaust pipe. The subject hybrid exhaust manifold can be adapted to fit within a very small space envelope in the engine compartment.

Abstract: The disclosure embraces a method of and apparatus for expanding circular cylindrical metal tubing, pipe or tubular members wherein an expanding construction embodies expandable fingers or members and cone-shaped means cooperating with the fingers or members for expanding tubing, pipe or tubular members. The method and apparatus involves the use of power means for expanding the fingers by relative movement of cones engaging the fingers, the method and apparatus including selectable indexing means for determining the amount of expansion of tubing, pipe or tubular members.

Abstract: A replacement muffler which can replace original equipment mufflers with substantially no modifications thereto, and methods for producing the same are disclosed. The replacement muffler is provided with a muffler body which only approximates the body of the original equipment muffler and a pair of replacement muffler nipples secured to the muffler body, having diameters substantially equal to the corresponding nipple diameters of the original equipment muffler and having lengths adapted to produce a nipple-to-nipple length substantially equal to the corresponding length of the original equipment muffler. The replacement muffler may be produced with a six to seven fold increase in production line efficiency by customizing only the nipple portions of the replacement muffler.

Abstract: An air gap pipe and a method for forming the same are provided. This air gap pipe includes a non-linear outer pipe and an inner pipe of identical configuration disposed concentrically within the outer pipe. The inner pipe is supported by resilient dimples in the outer pipe. The outer pipe is placed in a condition for receiving the inner pipe by longitudinally cutting the outer pipe in half with a pre-programmed plasma arc or laser cutting apparatus. The two halves of the outer pipe are secured together to provide vents, if necessary, for selective dissipation of heat.

Abstract: A technique for securing a tube to a flange includes the steps of inserting the end of the tube into an aperture provided on the flange from the first side of the flange such that a portion of the tube extends at least to, and preferably beyond the second side of the flange opposite the first side. A ceramic plug is optionally inserted into the end of the tube to prevent weld spatter and tube burn-through. The tube is then welded to the flange about the circumference of the tube from the second side of the flange, and that portion of the tube which extends beyond the second side of the flange is removed by grinding to produce the finished product.

Abstract: A replacement muffler which can replace original equipment mufflers with substantially no modifications thereto, and methods for producing the same are disclosed. The replacement muffler is provided with a muffler body which only approximates the body of the original equipment muffler and a pair of replacement muffler nipples secured to the muffler body, having diameters substantially equal to the corresponding nipple diameters of the original equipment muffler and having lengths adapted to produce a nipple-to-nipple length substantially equal to the corresponding length of the original equipment muffler. The replacement muffler may be produced with a six to seven fold increase in production line efficiency by customizing only the nipple portions of the replacement muffler.

Abstract: Double walled tubing, a method and apparatus for producing the same are disclosed. First and second metal tubes of substantially identical diameters are selected. One end of the second tube is expanded, and the first tube is pushed into the second tube. By mounting the first tube on a mandrel having a mandrel ball with an outer diameter which approximates the inner diameter of the first tube, any creases in the first tube caused by the insertion will be removed by the mandrel ball upon withdrawing the mandrel from the first tube.

Abstract: A universal heat shield which may be varied in length and shape to fit a variety of mufflers, catalytic converters, and the like, is disclosed. A pair of metal sheets, each of which includes a pair of planar members intersecting at a crease line, a pair of slots and a pair of tabs, are fastened to each other with screws which extend through the slots. The shield is fastened to the muffler by strapping the tabs to opposite ends of the muffler body.

Abstract: Various universal muffler assemblies are disclosed which allow one or more muffler nipples to be secured to a selected muffler body at the time of installation.

Abstract: A technique for threadedly securing muffler nipples to a muffler body is disclosed. The muffler nipples are provided with a threaded portion which is adapted to be inserted into a bushing attached to the muffler body, threadedly secured thereto, and tightened with a predetermined torque designed to prevent the nipples from unthreading or loosening within the muffler body.