How to Modify Chainsaw Muffler in 4 Different Ways

Patrick McMann

Knowledge Based

When working with a chainsaw, you might encounter problems that slow down its performance. Factors like exhaust flow, backpressure, and fuel efficiency can impact how well your cutting machine runs. One way to address these issues is to improve the chainsaw performance exhaust system.

That’s where the concept of the chainsaw muffler mod comes in. It involves modifying the cutting machine’s muffler to increase exhaust flow, reduce backpressure, and improve engine performance.

This simple muffler modification can help you achieve better cutting results and complete tasks faster with less effort. In this guide, I’ll discuss the types of mufflers and how to modify a chainsaw muffler to boost your cutting tool’s performance. So, no more struggling with poor-cutting results.

modding a chainsaw muffler

How to Modify Chainsaw Muffler?

Modifying a chainsaw muffler involves removing the internal baffles or drilling holes in the muffler casing. Or you can use a pre-modified muffler to replace the old muffler. This increases the exhaust flow and reduces the backpressure to improve chainsaw performance. 

Modifying an Existing Chainsaw Muffler

You now already know how to install a pre-modified or DIY cutting tool muffler, but what about modifying a pre-existing one? Here’s how to modify a Husqvarna chainsaw muffler or any other brand of chainsaw muffler and the materials you’ll need:


  • Drill.
  • Metal drill bits.
  • Wrench.
  • High-temperature sealant.
  • Optional: Echo chainsaw muffler mod kit or any other brand’s mod kit.

Step 1: Remove the Muffler

Remove the screws from the muffler using a wrench and remove it from your cutting machine engine. Keep the screws in a safe place to avoid losing them.

Step 2: Disassemble the Muffler

If you are using a muffler mod kit, follow the manufacturer’s instructions to disassemble the muffler and remove internal baffles and screens. But if you are not using the kit, skip to Step 4.

Step 3: Install the Muffler from the Mod Kit

Install the modified components from the mod kit per the manufacturer’s instructions.

Step 4: Modify the Existing Muffler

You can modify the existing muffler by removing the internal baffles. This will increase exhaust flow. Or use a drill and metal drill bits to make additional holes in the muffler. But be sure to drill in a pattern allowing increased exhaust gas flow.

Step 5: Reassemble the Muffler

Once you’ve done all the modifications, reassemble the muffler. Next, apply a high-temperature sealant to create a tight seal between the muffler and the engine.

Step 6: Test the Chainsaw

Switch on your cutting machine for the test performance with the chainsaw muffler. Monitor the noise levels and power output and make adjustments if necessary.

Replacing the existing muffler with a pre-modified one can provide a more reliable solution. Here are the types of common pre-modified or performance chainsaw mufflers you’ll find:

1. Barkbox Chainsaw Muffler

A barkbox muffler is designed to boost the cutting tool’s throughput by increasing exhaust flow and reducing back pressure. It consists of a casing that houses a series of chambers and baffles. The unique barkbox chainsaw muffler design also decreases noise levels.

Installing a Barkbox Chainsaw Muffler

Here are the materials required and the steps to installing a barkbox chainsaw muffler:


  • Barkbox chainsaw muffler.
  • Wrench.
  • High-temperature sealant.


  1. Use a wrench to unscrew the nuts on the old muffler and remove it from the chainsaw.
  2. Remove any debris or buildup from the exhaust port.
  3. Install the Barkbox muffler onto the exhaust port of the cutting machine engine, and ensure that the gasket is aligned correctly.
  4. Tighten the muffler bolts or screws using the wrench.
  5. Apply the sealant on the joint where the muffler connects with the engine switch on the cutting tool and check for any leaks or abnormal noise levels.
  6. Adjust the carburetor as necessary to ensure proper fuel mixture and optimal performance.

2. Ported Chainsaw Muffler

A ported chainsaw muffler is modified with additional ports or openings to increase exhaust flow and reduce backpressure. It involves drilling or cutting holes into the muffler casing with the ports placed strategically, allowing for a more efficient exhaust flow.

However, keep in mind that porting a muffler may also increase the noise levels of your chainsaw, which may not be suitable for you.

Create a Ported Chainsaw Muffler

Modifying a chainsaw muffler to make it ported involves more than installation. Here are the materials needed and the steps to create a ported muffler:



  1. Use a wrench to unscrew the nuts on the old muffler and remove it from the gas powered chainsaw.
  2. Remove any debris or buildup from the exhaust port.
  3. Use a measuring tape to mark the places on the muffler where you want to drill the holes. But make sure the ports are evenly spaced and placed at the bottom of the muffler.
  4. Use a power drill and the drill bit to create even depth ports.
  5. Use a grinding wheel or sandpaper to remove rough edges or burrs for consistent airflow.
  6. Apply the sealant to the joint between the muffler and the engine and reattach the muffler to the cutting tool engine. Lastly, test the muffler’s performance.

3. DIY Chainsaw Muffler

A DIY chainsaw muffler is a custom muffler made from scratch using basic materials and tools. The idea behind it is to create a muffler tailored to your specific cutting machine and needs without using expensive or specialized equipment.

Creating a DIY muffler involves designing and fabricating the muffler casing and installing new baffles and ports.

But as cost-effective as this customized muffler is, you need significant skill and knowledge to design and install it. Therefore, it’s crucial to research and plan the design before creating a DIY chainsaw muffler.

Create a DIY Chainsaw Muffler

If you’re an experienced DIY enthusiast and are skillful with metalworking, you can create your own DIY chainsaw muffler. Here are the materials required and the steps to make a DIY muffler:


  • Sheet metal (at least 1/16″ thick).
  • Welding equipment (MIG, TIG, or oxy-acetylene).
  • Metal cutting tools (jigsaw, hacksaw, or plasma cutter).
  • Drill and metal drill bits.
  • Clamps or vise.


  1. Use a muffler design book or software to design to determine the optimal shape, size, baffles, ports, and chambers for your DIY muffler. To design a muffler, first consider the noise restrictions in your area and the size and power of your cutting tool.
  2. Pick a metal cutting tool of your choice and cut the metal sheet to your desired size and shape for the muffler casing. Also, cut additional pieces for ports, baffles, and chambers.
  3. Use welding equipment to weld the metal pieces to create a muffler casing. Then use a drill and drill bits to create openings in the casing for baffles and ports installation.
  4. Lastly, assemble the muffler and attach it to your chainsaw engine. Switch on the machine and test it out.

Learn More: How Hot Does a Chainsaw Muffler Get?

Frequently Asked Questions

How can I make my chainsaw muffler quieter?

You can add a muffler silencer or a sound-dampening baffle to make your chainsaw muffler quieter.

Can you put a muffler on a chainsaw?

Yes, you can install a muffler on your chainsaw if it doesn’t have one. In fact, it is crucial to install a muffler to reduce noise levels and comply with local noise restrictions.

What does a chainsaw muffler do?

A chainsaw muffler reduces exhaust emissions and the noise level of the cutting machine. It works by restricting exhaust gases and directing their flow through baffles.

What is the temperature of the exhaust on a chainsaw?

The exhaust temperature on a cutting machine can vary based on the make and model of the machine and operating conditions. However, the average exhaust temperature can range from 400 to 800 degrees Fahrenheit.

What makes a muffler sound deeper?

A muffler will sound deeper if it has a large internal volume or a straight-through design that allows for more exhaust flow.

What reduces exhaust sound?

Exhaust sound in a chainsaw can be reduced using sound-absorbing materials in the muffler, such as fiberglass or steel wool. They help to absorb and dampen the sound waves. Additionally, a large internal volume or more restrictive muffler baffling can also help reduce exhaust sound.

Final Thoughts

Modifying a chainsaw muffler can have numerous advantages for your machine, such as increased performance, reduced noise levels, and improved fuel efficiency. Whether it’s a DIY modification or installing an aftermarket muffler like the Barkbox, with the right tools and instructions, the process is really straightforward.

By following the steps outlined in this article on “How to Modify Chainsaw Muffler,” you can enjoy a more efficient and quieter chainsaw experience.

Patrick McMann