Basics: This is how silencers are made

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Basics: This is how silencers are made
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Basics: This is how silencers are made

Basics: This is how silencers are made
Visiting the Shark company

2Wheels at the Shark company in Soncino, northern Italy, observed which work steps are necessary before a new silencer sees the light of day.

07.09.2009

Silencers differ in two types: On the one hand, there are reflection dampers that dampen the sound through different chambers inside the system. On the other hand, there are absorption dampers, which cover around 95 percent of the market and where insulation wool wrapped around the inner pipe ensures the necessary noise reduction. 2Rader was shown the manufacturing process of the much more frequently used absorption models at Shark.

Around 20 zealous employees have ensured that around 15,000 final pots leave the company every year since 1981. No wonder – after all, adding an accessory damper is one of the most popular conversion measures on a motorcycle. Why? Quite simply: Most series systems are bulky, heavy and not exactly pretty. In addition, their sound often falls by the wayside. Almost all retrofit dampers from the accessories are slimmer, more delicate, appear sportier – also in terms of sound – are usually much lighter and cost less than the standard pot.

Step 1


Basics: This is how silencers are made

In the first step, huge perforated sheets made of stainless steel are first cut to the required size and then rolled into a tube on a machine.

Step 2


Basics: This is how silencers are made

Lots of spot welds over the entire length of the perforated sheet ensure that the later inner tube always stays in shape.

Step 3


Basics: This is how silencers are made

A short metal tube is welded into the exhaust end, which later serves as a guide for the dB absorber (also known as a flute).

Step 4


Basics: This is how silencers are made

Two metal hooks are welded onto the front end cap towards the manifold, into which the safety springs are attached when the exhaust is installed.

Step 5


Basics: This is how silencers are made

Now the front cap with the attached spring hooks is welded to the perforated inner tube.

Step 6


Basics: This is how silencers are made

An employee wraps insulating material made of heat-resistant glass fiber material in several layers as tightly as possible around the perforated inner tube.

Step 7


Basics: This is how silencers are made

After welding on the inner rear end cap, a narrow steel strut is inserted and welded. It will later serve as a fastening for the exhaust bracket.

Step 8


Basics: This is how silencers are made

So that the outer shell made of aluminum, stainless steel, carbon or titanium can be pushed unhindered over the blank, the protruding weld seam must be ground off.

Step 9


Basics: This is how silencers are made

Before the carbon outer shell is pushed on, the blank is given a heat protection layer made of special textile and aluminum sheet.

Step 10


Basics: This is how silencers are made

The visible end pipes protruding from the rear of the exhaust, which are welded to the outer cap, must be cut to the required length from bar material with a chop saw.

Step 11


Basics: This is how silencers are made

In several work steps, the end tube is bent and crimped on special presses. As a result, the pipe end not only looks pretty, it also no longer has any sharp-edged burrs.

Step 12


Basics: This is how silencers are made

The end cap, which has already been welded to the bent end tube, is stamped with the brand logo and e-mark.

Step 13


Basics: This is how silencers are made

With machine power, the finished rear end cap is pressed over the outer shell of the silencer. In order not to damage the sensitive carbon shell, you need a sure instinct.

Step 14


Basics: This is how silencers are made

The almost finished silencers are placed in templates in order to drill the holes for the exhaust bracket and for all the rivets for the end caps and the brand logo.

Step 15


Basics: This is how silencers are made

An assembly professional only needs a few seconds to rivet the end caps with the help of a tried and tested riveting gun. And the pot holds together.

Step 16


Basics: This is how silencers are made

On the occasion of the 2Rader visit, the company boss insisted on attaching the company logo himself.

Step 17


Basics: This is how silencers are made

Now insert the dB absorber and rivet it, and the silencer is ready. Finally, the shipping department cleans and polishes the pot, puts it in a suitable box and sends it to you.

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