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I'm not cracked up uver a crack!

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  • #1

    I'm not cracked up uver a crack!

    My right muffler on my XJ cracked almost completely around. The only thing holding it together was the crossover flange that spanned where the crack was. I welded it up but considering how many other times I’ve had to weld on this exhaust I know it’s only a matter of time before it will crack again. I’ve had to weld the mufflers on to the collectors already and patch a bunch of rust out in both collectors. My headers seam to be ok though. What I need is a pair of XJ mufflers (I like the look and length of them) to replace mine. I’ve seen several on eBay when I didn’t need them, but none now. I really want to stay with the original look so that eliminates the MAC sets.

    If any one here knows where a pair could be found PM me. I don’t care if there are scratched or there is some rust since I’ll weld them on and paint them black. I don’t even mind a dent or 2 since I can pull the dents out.

    Louis

    [
    "There is no mechanical problem so difficult that it cannot be overcome by
    brute strength and ignorance" And possibly some Mouse Milk!
    '82 XJ1100J
    LED Dir and running lights
    LED Tail/Brake lights (4) one flashing
    Modulated H/L
    PIAA Driving lights
    YICS Eliminated
    750 FD

    Yamaha Factory X-1 Fairing and Luggage
    Tags: None
  • #2
    A lot of times, it's cheaper to buy a whole parts bike with a decent exhaust system on it than it is JUST the mufflers. Just keep an eye on Ebay. I have a feeling that when the cold weather comes back, a lot of the fair weather riders will be selling again. Just be patient.. and outbid me!


    Tod
    Try your hardest to be the kind of person your dog thinks you are.

    You can live to be 100, as long as you give up everything that would make you want to live to be 100!

    Current bikes:
    '06 Suzuki DR650
    *'82 XJ1100 with the 1179 kit. "Mad Maxim"
    '82 XJ1100 Completely stock fixer-upper
    '82 XJ1100 Bagger fixer-upper
    '82 XJ1100 Motor/frame and lots of boxes of parts
    '82 XJ1100 Parts bike
    '81 XS1100 Special
    '81 YZ250
    '80 XS850 Special
    '80 XR100
    *Crashed/Totalled, still own

    Comment

    • #3
      Update!

      When I got home after a ride through west central Arkansas the day before yesterday and pulled my helmet off, I heard a small amount of exhaust noise coming from where I had welded up the right muffler. Got down on the floor and saw a small hole on the bottom I had missed when welding it up .

      Well, I went down to weld it up a short while ago, ground the black finish off of it, hooked up the MIG, got down close and started cussing!!!!! Another crack right around the muffler. This time at the front of the balance tube.

      I figured this would take a little more welding and that I had better put a pair of jeans and shoes on instead of the shorts and bare feet that I had. As I passed the computer I thought I'll just see if there is a Mac system listed on eBay. A search under xj1100 showed no Mac systems but did show a complete XJ110 system with a buy it now price of 299.99 and a current bid of 49.99. Needless to say, I hope he ships it fast!

      I'll probably not paint it black until after the Talimena Rally because I don’t think SWMBO would let me spend the money for paint ($26.00 a pint) and having it sandblasted after just having 'wasted 339.94 on the exhaust fot that ___ _____ ____ __ ____(fill in the blanks). Especially after just yesterday inadvertently admitting that I had over $3000.00 tied up in that ___ _____ ____ __ ____(fill in the blanks).

      Louis
      "There is no mechanical problem so difficult that it cannot be overcome by
      brute strength and ignorance" And possibly some Mouse Milk!
      '82 XJ1100J
      LED Dir and running lights
      LED Tail/Brake lights (4) one flashing
      Modulated H/L
      PIAA Driving lights
      YICS Eliminated
      750 FD

      Yamaha Factory X-1 Fairing and Luggage

      Comment

      • #4
        What type of filler rod or wire did you use ? Try a 309 or 309L rod or wire that should solve your cracking problems.
        BDF Special
        80SG Vetter bagger 1196 Wiseco big bore kit, Mega Cycle Cams, slotted cam gears, ported and flowed head, bronze intake seats, Dyno Jet kit, Dyno coils and Mikes XS air pods, Venture cam chain adjuster,Geezer's regulator, Clutch mod, Mac 4 into 1 with custom built and tuned baffle, Oil cooler,MikesXS emulators mod.
        Dyno tuned to 98 hp at the rear wheel.

        Comment

        • #5
          What we do for the things and the people that we love.
          http://farm2.static.flickr.com/1241/1480921818_241eade448_s.jpg

          Comment

          • #6
            I just used my MIG with .023 wire that I had in it. The exhaust is so thin from rust I believe it's the chrome and black paint thats holding it together. The bottom of both collectors where the headers join are fill weld and small pieces of plate welded in. When I wire brushed (by hand) I was afraid of the rust, I mean metal caving in. Except for the header pipes themselves, the bottom of the collectors are now probably the strongest part of the whole system.

            Louis
            "There is no mechanical problem so difficult that it cannot be overcome by
            brute strength and ignorance" And possibly some Mouse Milk!
            '82 XJ1100J
            LED Dir and running lights
            LED Tail/Brake lights (4) one flashing
            Modulated H/L
            PIAA Driving lights
            YICS Eliminated
            750 FD

            Yamaha Factory X-1 Fairing and Luggage

            Comment

            • #7
              I have been watching that exhaust also... You don't see a set this nice very often.. I'd hate to see them get painted instead of polished. You're going to do what you want... it just seems a shame.



              Tod
              Try your hardest to be the kind of person your dog thinks you are.

              You can live to be 100, as long as you give up everything that would make you want to live to be 100!

              Current bikes:
              '06 Suzuki DR650
              *'82 XJ1100 with the 1179 kit. "Mad Maxim"
              '82 XJ1100 Completely stock fixer-upper
              '82 XJ1100 Bagger fixer-upper
              '82 XJ1100 Motor/frame and lots of boxes of parts
              '82 XJ1100 Parts bike
              '81 XS1100 Special
              '81 YZ250
              '80 XS850 Special
              '80 XR100
              *Crashed/Totalled, still own

              Comment

              • #8
                Tried to PM you but your box is full...

                Would you be interested in maybe going in halves with me on this set? I would love to have those headers... and you need the mufflers. I wouldn't want to pay more than 125 for them since I got my last set with a mostly complete bike for less than that. So if you're going to do the buy it now option... it's out of my price range.


                Tod
                Try your hardest to be the kind of person your dog thinks you are.

                You can live to be 100, as long as you give up everything that would make you want to live to be 100!

                Current bikes:
                '06 Suzuki DR650
                *'82 XJ1100 with the 1179 kit. "Mad Maxim"
                '82 XJ1100 Completely stock fixer-upper
                '82 XJ1100 Bagger fixer-upper
                '82 XJ1100 Motor/frame and lots of boxes of parts
                '82 XJ1100 Parts bike
                '81 XS1100 Special
                '81 YZ250
                '80 XS850 Special
                '80 XR100
                *Crashed/Totalled, still own

                Comment

                • #9
                  tinman,

                  It's not the welds cracking. It's just cracking from the balance tube, completly around the top, outside and bottom of the muffler back to the balance tube. It did it at the rear of the balance tube, and now at the front, about an inch forward of the first crack. Actually, both times, the only thing holding the outer skin of the muffler together was where the balance tube attaches to the muffler

                  Louis
                  "There is no mechanical problem so difficult that it cannot be overcome by
                  brute strength and ignorance" And possibly some Mouse Milk!
                  '82 XJ1100J
                  LED Dir and running lights
                  LED Tail/Brake lights (4) one flashing
                  Modulated H/L
                  PIAA Driving lights
                  YICS Eliminated
                  750 FD

                  Yamaha Factory X-1 Fairing and Luggage

                  Comment

                  • #10
                    Tod,

                    Actually I need the headers also. Except for the balance tube, my whole system is welded together. When I bought the bike, there were sections of exhaust missing between the headers and mufflers that I filled in with some 4130 aircraft tubing I had. I even had to make my own heat shields.

                    I paid the buy it now price within two minuets of seeing the set. And it took me that long because PayPal was real slow loading today!

                    Louis
                    "There is no mechanical problem so difficult that it cannot be overcome by
                    brute strength and ignorance" And possibly some Mouse Milk!
                    '82 XJ1100J
                    LED Dir and running lights
                    LED Tail/Brake lights (4) one flashing
                    Modulated H/L
                    PIAA Driving lights
                    YICS Eliminated
                    750 FD

                    Yamaha Factory X-1 Fairing and Luggage

                    Comment

                    • #11
                      "What's all this about a Crack Pipe?"

                      Oh, sorry... I see now.
                      "Damn it Jim, I'm a doctor, not a mechanic!' ('Bones' McCoy)

                      Comment

                      • #12
                        Louis


                        TIG welding is superior. With a TIG you'll get a better weld and it's not as likely to burn through the thin wall of the exhaust.

                        Comment

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