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Old 08-11-2019, 09:09 AM
vybrano vybrano is offline
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Default Is exhaust supposed to be repaired or replaced?

When I ride or shake my exhaust I can hear rattling. Some huge metal part is moving freely inside (too big to be taken out by end pipe). I can't see any way how to dismantle this exhaust. However I have an angle grinder . and welding machine... .


Is this type of situation when you buy a whole new thing or you repair it??? I have zero knowledge about exhaust systems... .
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Old 08-11-2019, 09:19 AM
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I cant suggest what to replace it with as you dont list what it is to replace it with(ie the motor type, the Machine it is on ect)...
With that being said... its most likely a baffle floating about as a weld broke or something like that...
One could cut the end off, check out whats happening, fix that and weld the end back on...
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Old 08-11-2019, 11:05 AM
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I cant suggest what to replace it with as you dont list what it is to replace it with(ie the motor type, the Machine it is on ect)...
With that being said... its most likely a baffle floating about as a weld broke or something like that...
One could cut the end off, check out whats happening, fix that and weld the end back on...
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Old 08-11-2019, 11:09 AM
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Well you decide as to fix or buy... the Amazon is always cheap...But if you want something to do...Fix is always an option...

Its a 4 stroke... so its not so critical as to the end shape of it...
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Old 08-11-2019, 07:38 PM
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Grab a beer, 4-1/2 grinder, slice it open like a can of salty sardines...fix or remove rattly stuff...weld backup

UNLESS...you are under 21....then hand dad a beer and give him my directions
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Old 08-11-2019, 09:19 PM
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Well you decide as to fix or buy... the Amazon is always cheap...But if you want something to do...Fix is always an option...

Its a 4 stroke... so its not so critical as to the end shape of it...
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Grab a beer, 4-1/2 grinder, slice it open like a can of salty sardines...fix or remove rattly stuff...weld backup

UNLESS...you are under 21....then hand dad a beer and give him my directions
Is that rattling part not crucial to the function of the exhaust system and I can remove it?

I believe that exhaust system is supposed to suck air out of engine and make everything quieter? What is that part doing?
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Old 08-11-2019, 10:04 PM
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It's not for sucking....but to channel the gasses out..
Baffling hampers the flow.. but makes it louder..
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Old 08-11-2019, 10:08 PM
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He was probably referring to exhaust gas scavenging, wherein the preceding exhaust pulse in the pipe draws the one following it via vacuum...but who knows?

Repair or replace, both are feasible.
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Old 08-11-2019, 10:12 PM
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I kinda figured... but thats more of a 2 stroke exhaust where, internal geometry is a critical function for the operation of that type of engine...
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Old 08-12-2019, 09:23 AM
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Lol, this thread is killing me! If the busted muffler isn't causing a performance hit then cut open the end and pull the loose baffle and toss it. Reweld the end and ride on. If it bothers you buy a new muffler. It really is that simple.
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Old 08-12-2019, 09:52 AM
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Hey Wes, not everyone has a welder and all those other cool toys.

Are you offering your services?

There's other ways: He could take a hacksaw and cut the rear of the muffler off (the end of the widest part), remove the offending bits and screw it back together with sheet metal screws. Maybe add some heat resistant fiberglass wadding around the circumference to absolutely positively prevent leaks...
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Old 08-12-2019, 04:48 PM
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Or cut it in half, remove loose pcs while drinking canned beverage of choice, then beer can into 2 strips and use 2 hose clamps to secure muffler into one pc again...kinda like this

A welder would be best, if you get into fabbing you will want a welder and 4-1/2 in grinder
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Old 08-12-2019, 08:54 PM
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Quote:
Originally Posted by BigWes View Post
Lol, this thread is killing me! If the busted muffler isn't causing a performance hit then cut open the end and pull the loose baffle and toss it. Reweld the end and ride on. If it bothers you buy a new muffler. It really is that simple.
^^^ what he said ^^^
You have a grinder, you have a welder, and itís already broke. Youíre not really going to break it any worse and you needed a new one anyway if you somehow do.
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Old 08-13-2019, 08:53 AM
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Quote:
Originally Posted by Bansil View Post
Or cut it in half, remove loose pcs while drinking canned beverage of choice, then beer can into 2 strips and use 2 hose clamps to secure muffler into one pc again...kinda like this

A welder would be best, if you get into fabbing you will want a welder and 4-1/2 in grinder
This man obviously enjoys tinkering with and repairing his own stuff! Obviously this is a temporary fix. Fortunately he will have to prepare more patch material for the next repair when the time comes! Lol!

I approve of this post for obvious reasons!

---------- Post added at 09:53 AM ---------- Previous post was at 09:40 AM ----------

Oh yes, and for what it's worth....if anyone wants a tip into cutting thin metals and doing so you can buy metal cutting blades to fit your sawzall if you have one. The advantage to this is the metal is being cut away versus ground away often losing less material in the cutting process as it makes a smaller kerf than a thick grinding wheel would. The results are easier to piece back together in a cleaner fashion. Just something to consider. Just be aware cutting metal with a sawzall takes practice.
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Old 08-14-2019, 05:36 AM
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My apologies for offending anyone with my earlier response to Helion.
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Old 08-14-2019, 08:07 AM
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I still didn't got to do it. Everyday I'm keeping this repair for tomorrow.

Cutting that exhaust open and welding broken part to it's place will be easy. What I'm affraid of is welding that muffler back together - because while welding I'm blowing holes into even thicker materials. Not even talking about this paper thin metalsheet that is used on this muffler. That job will suck. So I'm still riding around with rattling muffler.


Is that inner part usually connected at the end or beginning of muffler? I wanna slice it open like you cut a cucumber - but dunno if to cut it at the pipe side or fumes out side.
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Old 08-14-2019, 08:38 AM
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it's connected to the end cap usually

with your style exhaust I'd almost bet it's originally part of that extruded tip ..
basically a slip in fit.
So cutting off the tip instead of the entire cap, might get it out without distorting the exhaust sidewalls at all.

Then you can weld it to the tip, and the tip back onto the cap...

If you can fish for it with a piece of hooked wire, and can get it close to the opening,
you might be able to secure it there with some tack welds through the tip of the exhaust.
It's not nice
(since it likely rusted off and the seam will be all but clean and nice, thus the weld will be terrible)
but it might buy you some time to gather confidence in cutting it open, or buying a new one.
Frankly it might hold even longer if instead of welding (to rusted steel)
you'd use JB Weld epoxy to glue the baffle tube back to the cap *shrugs*

In any case: cutting it open or buying a new one are the only two options for a permanent fix.

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Old 08-14-2019, 08:17 PM
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Quote:
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My apologies for offending anyone with my earlier response to Helion.
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Old 08-15-2019, 12:30 AM
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Well, that was a rather anticlimactic ending.

It has just this round plate with a few holes in it. That broke off.
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Old 08-15-2019, 02:09 AM
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Might not be best weld on this forum , but better than these 2 tack welds from the factory that were holding it originally.
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