I made my own muffler... Not for a Warrior, but a quadsport. Here's how I did it:
Top is a stock Warrior muffler. Next down is a Jardine for a quadsport. Next is a driveshaft I found at a house I bought. Last is a stock quadsport muffler (sorta hacked up).
Pipe with some holes drilled in it. Looks about right... I read that Harley uses 8 rows of holes, so I went by that.
Gettin ready to wrap.
I read that stainless steel wool protects the fiberglass from blowing out, but I only had regular steel wool, so I used that. Later a friend told me he knew a guy that stuffed his muffler with steel wool and caused a fire.
Oops. Oh well, hasn't happened to me so far.
Next is the fiberglass matting I had. Its pretty thick and should last a long time. Kinda looks like a stoggie, lol. Nice n tight too....
Nope, fiberglass doesn't burn.
Wrap n stuff! Used some kind of wire screen to hold it together to make it easier to stuff.
Welded on the brackets and put some high temp black paint on.... Doesn't look too bad for stuff I had laying around.
Performance is great! I had to drill my main jet up several sizes after installing it. Nice n quiet just putting around... I could sneak up on you as long as you didn't see me,,, but open up the throttle and it screams pretty good. I love it!
Just need to figure out a spark arrestor now.
Oh, its not as heavy as it looks either. I'd guess somewhere around 3-4 lbs.... I know its not as heavy as a 5lb barbell plate. Driveshafts are light. And the stiff, round design makes the most sense holding in the pressure (sound = pressure). The "flat" sides of on oval will flex and let the sound out.