Author Topic: Rusted Muffler Repair (Read 3437 times)

Apexxn · « **on:** November 28, 2012, 01:29:45 PM »

This 400F exhaust is in excellent shape except it had some minor rust at bottom rear of the muffler.

Cutting the rust area out:

Filler piece cut and ready to tack in:

Ready for chrome:

iron_worker · « **Reply #1 on:** November 28, 2012, 01:40:07 PM »

You may find that once you factor in the cost of chrome that it may have been worth it to just buy a new one. That is if you can find a new one.

IW

Old Scrambler · « **Reply #2 on:** November 28, 2012, 01:42:44 PM »

Nice Work..........At that location you could polish it and wait a while to see if any other weak spots show before chroming.

Killer Canary · « **Reply #3 on:** November 28, 2012, 01:47:14 PM »

Have any of you actually found a place that'll agree to re-chrome mufflers? I've always gotten a flat no.
Very curious about this.

iron_worker · « **Reply #4 on:** November 28, 2012, 02:11:04 PM »

I've never tried but I've done a little reading on the subject and the solutions they use to dip parts can easily become contaminated. With the mufflers being so dirty on the inside they probably don't want to deal with cleaning out all the carbon and possibly ruining a batch of chemical.

IW

Apexxn · « **Reply #5 on:** November 28, 2012, 02:56:07 PM »

I'm a nut about keeping everything OEM and what was actually on the bike. Does it really matter on this model and value bike, no but I sleep better at night.

It's on the very bottom so I could make it look better and just leave it because unless you get on the floor and look under nobody would ever know.

Yes I found a couple of places that don't care about the muffler being used. They said they have a special tank for that kind of part.

A used OEM unless it's NOS isn't going to look as nice as freshly chromed piece.

Rigid · « **Reply #6 on:** November 28, 2012, 03:09:28 PM »

Paint it with bbq paint and wrap with header wrap. When that collapses, a pop can can be riveted on and sealed with jb weld.

. I seriously doubt you have repaired the only thin spot in those pipes. Look right across the seam, pinholes. Seriously, i just cut those swiss cheese mufflers off and replace with aftermarket.

Apexxn · « **Reply #7 on:** November 28, 2012, 03:35:46 PM »

I already repaired across the seam just didn't post pics I figured the one side was enough.

Once I had access I was able to slide a small mirror around inside. I'm not worried, this isn't the first muffler I've repaired.

Bbq paint, pop can with rivets, jb weld, uh yea not how I do things but we all do things our own way on our own bikes.

Rigid · « **Reply #8 on:** November 28, 2012, 03:55:33 PM »

Your obviously superior in all matters of pipe repair and are able to succeed where many others have failed. Carry on.

Stev-o · « **Reply #9 on:** November 28, 2012, 08:56:25 PM »

That's the best repair I have seen. I should post a pic of the repair the PO did on my 550F muffler....it's embarrassing!

Apexxn · « **Reply #10 on:** November 28, 2012, 09:32:18 PM »

Steve-o post a pic I dare ya.

Hey Rigid wasn't trying to offend you, just posting up one way this could be taken care of, not the best or the only way.

Killer Canary · « **Reply #11 on:** November 29, 2012, 07:25:02 AM »

Your fix job does look solid; no criticism from me. If you've found the rest to be good AND found a willing plater, it's worth considering. Being a 400F it would be worthwhile to keep it original. If you decide to re-chrome, I'd love to see how it turns out.

bjatwood · « **Reply #12 on:** November 29, 2012, 12:31:18 PM »

Rigid was just trying to spend your money

hoodellyhoo · « **Reply #13 on:** November 29, 2012, 06:18:18 PM »

holy cow! You were actually able to weld that paper thin metal! I've only done a tiny bit of welding but I know enough that it would take me forever to get good enough to be able to do that.

scottly · « **Reply #14 on:** November 29, 2012, 06:22:55 PM »

A little tip: drill a small drain hole at the bottom rear of the muffler. This will allow condensed moisture to drain out, rather than getting trapped and doing the type of damage you have just repaired.
BTW, where in SoCal are you? That general area is larger than some states!

Stev-o · « **Reply #15 on:** November 29, 2012, 06:25:52 PM »

Quote from: Apexxn on November 28, 2012, 09:32:18 PM

Steve-o post a pic I dare ya.

A bad pic but a repair this horrible doesn't deserve any better!
[not done by me!!]

scottly · « **Reply #16 on:** November 29, 2012, 06:32:36 PM »

At least he didn't rivet a pop can on and slop a bunch of JB weld on it.

Stev-o · « **Reply #17 on:** November 29, 2012, 06:34:40 PM »

Quote from: scottly on November 29, 2012, 06:32:36 PM

At least he didn't rivet a pop can on

I think that would look better

Apexxn · « **Reply #18 on:** November 29, 2012, 06:38:28 PM »

Hoodellyhoo, I do a lot of 40+ year old car and truck rusty sheetmetal repair so this piece was easy. I'm sure you can do it with a little practice. Remember this is just a bunch of spot welds you can't lay down a bead on sheetmetal as the photo that Steve-o posted clearly shows, lol.

Good tip on the hole I hadn't thought of that. And I just dropped off the muffler to the chromer today. Now I'll have to drill through brand new chrome.....aint that a #$%*.

I'm in a small town nobody here has probably heard of, Castaic.

Scottly, no comment on the jb weld.

CycleRanger · « **Reply #19 on:** November 29, 2012, 06:41:31 PM »

Quote from: Stev-o on November 29, 2012, 06:25:52 PM

Quote from: Apexxn on November 28, 2012, 09:32:18 PM
Steve-o post a pic I dare ya.

A bad pic but a repair this horrible doesn't deserve any better!
[not done by me!!]

"See, I told you you could weld to rust!"

Stev-o · « **Reply #20 on:** November 29, 2012, 06:50:22 PM »

In defense of the PO, it's not really noticeable unless you're looking for it.
If you look closely, you'll notice the pic is of the underside of the muffler.

scottly · « **Reply #21 on:** November 29, 2012, 07:02:54 PM »

Quote from: Apexxn on November 29, 2012, 06:38:28 PM

I'm in a small town nobody here has probably heard of, Castaic.

I've heard of it, and thought it was near the Grapevine, but I had to Google it. I used to ride dirt-bikes at Hungry Valley, and traveled 138 on a regular basis, when I lived in Apple Valley.

Mo · « **Reply #22 on:** November 29, 2012, 08:33:16 PM »

Just curious, but does anyone have a decent source for affordable, stock-looking after market mufflers?

MoMo · « **Reply #23 on:** November 30, 2012, 12:40:58 AM »

Quote from: malkaysi on November 29, 2012, 08:33:16 PM

Just curious, but does anyone have a decent source for affordable, stock-looking after market mufflers?

David Silver in England (now in Hanover, PA also). It is a replica...Larry

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Author Topic: Rusted Muffler Repair (Read 3437 times)