Topic: Muffler road rash, any ideas on how to fix?

[manjisann]

I bought this bike, and aside from the lovely road rash on these pipes (and some surface rust on the headers) the mufflers look to be in decent shape. I was originally thinking I could just fill in the road rash with welding rod (using my oxy gas setup) but a neighbor who is certified in welding (I haven't seen him weld, he just says he is) says that my idea will more likely blow holes in the pipe rather than fill it. I am gonna be painting them with high temp paint. I am trying to save money, so buying a new set is pretty much out, unless I could get it for $50  . If I welded some small rods to it, could I pull the rash out mostly, then fill in what little is left with welding rod? Would removing the baffles allow me to do something from the inside?  Looking for practical suggestions. I had thought of getting a new cone, Terry in Australia recommended a good site for that, but the problem I see is there are other little tubes welded into the muffler, so it's not just a cone like I had originally thought.

Thanks,

Brandon

[tomkimberly]

If you are going to paint them, just filling the dents with JB Weld.


Tom

[manjisann]

If you are going to paint them, just filling the dents with JB Weld.

I've thought about that, my only concern was the JB weld would bubble off if it gets too hot. I know it's good up to 300 F, do mufflers ever get that hot?  Has anyone ever tried this?

Brandon

[robe0531]

can you fill it in with lead like they do with auto panels i dont think the pipes will get that hot that far down the pipe

[Alan F.]

Personally, I'd just wet sand them with 800 grit and paint them.  Were you going with flat black?  That rash might not look so bad in flat black compared to shiny rash catching the light...
-A

[JS550]

Can you switch em around? The inside lower doesnt look as bad. Maybe black em & put the bad one on the bottom & roll the roughest part to the inside (tire side).

[manjisann]

Can you switch em around? The inside lower doesnt look as bad. Maybe black em & put the bad one on the bottom & roll the roughest part to the inside (tire side).

We would have to cut the mufflers off the pipes and also relocate the mounting bracket.... but the idea has some possibilities. Anyone else have any thoughts on this? I've never welded, other than my sad sad job on the pipes of my 500. If I had access to a mig welder, would this me doable for someone with reasonable skills (ie my neighbor)

Personally, I'd just wet sand them with 800 grit and paint them.  Were you going with flat black?  That rash might not look so bad in flat black compared to shiny rash catching the light...
-A

Yeah, dull black vht is what I was planning on using.

With regard to the idea of just rotating the muffler and using the unbuggered side, would this cause any problems with the internal tubes or baffles are anything like that, does anyone know?

Thanks guys, any other ideas anyone??

Brandon

[Alan F.]

maybe a chrome heat shield?  or maybe one that you can fab up yourself and paint, held on by hidden hoseclamps from behind?

have a look:   http://www.jcwhitney.com/autoparts/ItemBrowse?storeId=10101&Pr=p_CATENTRY_ID%3A100000140500&productId=100000140500&catalogId=10111&langId=-1&rlid=group_listing

[Alan F.]

DUDE!  How cool would this look over a flat black muffler?

http://cgi.ebay.com/ebaymotors/CHROME-11-3-4-FLAME-EXHAUST-PIPES-HEAT-SHIELD-4-HARLEY_W0QQitemZ220407415094QQcmdZViewItemQQptZMotorcycles_Parts_Accessories?hash=item33514e4136&_trksid=p4506.c0.m245&_trkparms=72%3A1171%7C65%3A12%7C39%3A1%7C240%3A1318

[manjisann]

  The flames are a bit over the top for me and the design I have going, but definately cool!  That is an idea, I could just weld some thin guage metal over the pipes, such that it wraps around and the welds are all on the tire side.... That is a reasonably workable idea. Thanks!

If anyone else has any ideas or pics of stuff they've done, let me know! Once I decide on what I want to do, I'll post the results here and on the build thread I'll be doing.

Brandon

[tygrant]

EASY... cut em off and go straight pipes 

[manjisann]

EASY... cut em off and go straight pipes 

Everyone would here me coming for sure, including the officer that gave me the ticket 

I am really thinking I'm gonna do something similar to what Alan F suggested, only instead of using bands, I'll just weld it in place.

Brandon

[Alan F.]

the trouble with welding is that even the cleanest weld will corrode and rot over a comparatively short time compared to the same part left alone.  If you weld to those thin pipes, they may develop pinholes and have a short service life.  The clamps will not affect metalurgy and will do the job.  Food for thought.
-A

[new2novas]

that would take forever to weld up (meaning to fill the dents right) and just as long to grind smooth, i would rather do spend that time panhandling to afford a new set....if they were irreplaceable you can fix them with a stud gun and a ton of patience and skill...yeah its doable, but for your neighbor to do that you would be mowin his lawn for the next 10 years

[manjisann]

Good thing he has a small lawn 

I'm still not sure what to do. I may just try to use JB weld to fill it in and shape it, and then spray it. If it starts to look crummy after that, I can worry about it at that time, maybe I'll have enough money to redo it right

Brandon

[new2novas]

keep updated, i'm curious as to how the jb will hold up to the heat and vibration...make sure to give it some good grinding where the jb will go for some tooth