Once I had my ZTW foam cutter working (here’s my original post), inspiration immediately struck! Why not make a muffler with foam baffles to bounce the air and sound around before leaving into the atmosphere? With the foam cutter and some Styrofoam that an item I recently purchased was packaged in, this was really easy to do.
As seen in the pictures after the “more”, I traced the inside of some 4 inch PVC pipe that was used in my original cloth-based muffler to the Styrofoam. Using this pattern, I then cut out four foam baffles to make the air snake around in the muffler before hitting my ears. The holes cut out were then used as spacers between the baffles, and everything was attached with a cord to keep things in their respective positions. Read more »










