1983 wr 250 muffler home made?

Hi. Has anyone made their own muffler at home for their husky particularly 83 year? Has anyone found a good cheap after market one? I was thinking I could use copper pipe for the internal then wrap with an aluminium pipe attaching the copper core with rivets. Copper would be easy to braze.....is copper a problem.....most cores are steel is it just expense or does copper have other problems?

Copper is not as rigid. The inside perforated steel part of the silencer is actually pretty light. The problem with creating something else is the mounting. I would modfy something, like a new take off sold on ebay or swap meet. There may well be aftermarket inexpensive silencers, chain saw parts and lawn mower spindles are shipped in from China for silly little money.

Talk to Darin- Dartyppyt. He welded a bunch up and may be able to steer you in the right direction for your year. But i haven't seen him here for a while.

Sorry i missed the MUFFLER part . Happy New Year

If you're riding on public land, as well as some private tracks, you'll need to have a spark arrestor incorporated into the silencer which will add to the build cost. The silencer/spark arrestor dirt dame mentions looks like a good one. Theres also a couple of aftermarket ones that have a 70's vintage look if you're thinking of equipping your 250WR. AMS racing and Speed and Sport both have them to fit the Husky 40mm stinger and the ones from Speed and Sport have the centrifugal spark arrestor incorporated, taking after the JR Krizman design. Last I checked they were in the $115 range.

If you still want to create your own you can find a used Answer on Ebay. They acquired JR Krizman decades ago so they have the centrifugal spark arrestor incorporated. You may have to change the inlet size to fit the Husky and they're a little long but it sounds like you're a tinkerer so modifying one shouldn't be an issue for you.

Thanks all. That gives me some ideas to follow.

you can go to a muffler shop and they will have a length of 3.5" exhaust tube and lengths of preforated tube in different sizes. you will need to measure the stinger diam and make sure your pref tube will fit over it. cut some 3.5" diam circles to make end plates and bore inlet and outlet holes, weld the pref tube into the outlet and then make sure it fits into the inlet cap. all you need then is to fix the end caps and fabricate a mount and the joiner pipe

I bit the bullet and bought an HVA muffler. Well built and light. Have not started the bike with it on yet but it looks good. The seat bolt does not clear the muffler lug though so I will need to grind the lug down a bit or just put the bolt in the other way.

I need to get or fabricate a speedo cable wire protector next.

The fork mounted wire cable protector/guide is the same from 1978 to 1987. Part number 15 17 306-01