Making a DynoMax Muffler - Behind The Scenes At Dynomax Muffler

1. The rolled steel (on left) is put through a machine that stamps the internal tubes of the muffler.

2. The steel exits the machine as a flattened louvered, cut-to-size, and stamped piece.

3. After the flattened steel receives the DynoMax logo imprint, it is fed into a machine that rolls it into louvered tubes and spits it out into a catch basket.

4. The canister-shaped louver tubing is assembled with its internal canister.

5. DynoMax employees wrap noise-damping fiberglass mat around the canister of the company's Super Turbo muffler.

6. At this time, the canisters are wrapped with high-frequency noise-damping fiberglass material to reduce any harsh, tinny sound. In the background, a DynoMax technician is inserting the canister into the muffler body

7. DynoMax muffler canisters are welded to the muffler bodies.

8. The secondary component is inserted in the canister body.

9. Next, a DynoMax technician loads the canister into a machine that places the outside cover on the muffler.

10. In this step, the DynoMax muffler head is spun-locked into place. With the head bead rolled, the muffler is complete. It is removed from the machine and fully inspected.

11. The muffler is loaded onto a line that delivers it to the automatic packaging system. A robotic arm prepares each boxed DynoMax muffler for shipment by placing them on a pallet.

12. Here is a shot of the hard-working DynoMax team in Harrisonburg, as they stand next to a pallet of Ultra Flo mufflers they made. Each pallet is taken to the shipping dock for distribution to performance and automotive retailers and installers.

13. Steel is cut to the appropriate width by the system's required pipe size. DynoMax owns one of six manufacturing machines worldwide that builds pipe through a continuous feed operation, meaning it takes rolled steel to piping without interruption.

14. The tube mill takes the flat steel and forms it into tubing.

15. A DynoMax technician takes the tubing, cut to the necessary length, and loads it for the next step.

16. A DynoMax technician shows the DynoMax cut-to-size tubing.

17. For a DynoMax system, the mandrel-bent piping is then welded to the muffler for inclusion in a complete system (shown).

18. DynoMax products are ready for cleaning and packaging. DynoMax technicians take both tubing and complete systems and prepare for shipment. DynoMax produces almost 4,000 miles of tubing per year.