Welding the cracks in mufflers

[XS1100 Newbie]

I have a left side muffler that broke most of the way around the shell. I thought i saw somewhere that this was common back close to the rear pegs where this one broke. My question is: can this thin metal be welded, or should i just look for a left side muffler?

[jaimes-duran]

I am pretty sure that it can be re-welded. My pipes have been re-welded before. Just about any local garage can weld it for a few bucks. It probably wont last a lifetime like some pipes are garunteed to but it will save you some money.

[Incubus]

MY right side muffler on one of my XS11's cracked right at the collector. It is very thin steel, but I good welder can fix it. My neighbor welded mine for me and it came out fine. Pick somebody good, though. The welder can do a lot of damage to that thin metal if he/she doesn't do it right. The thin steel will just melt away and leave a bigger hole if the welder doesn't know what he is doing.

Patrick

[CatatonicBug]

Russ79 welded one side of mine, then the other side cracked half-way around a month later, just under the heat shield. I rode over to a local weld shop, and they MIG welded it back together while still on the bike for $20.

[Silent]

I've welded mine and not had a problem since.

[Crazcnuk]

Derwat has welded a couple of sets, so far. None have recracked.

One thing I have found, is that a lot of these bikes have the rear mounts tightened to the point where they are bolted solid to the footpeg mount. Either the rubber damper is missing, or crushed to the point it can't do anything.

This creates a stress as the vibrations of the motor can't be dampened by the rubber.

[xsdad]

MY right side muffler on one of my XS11's cracked right at the collector. It is very thin steel, but I good welder can fix it. My neighbor welded mine for me and it came out fine. Pick somebody good, though. The welder can do a lot of damage to that thin metal if he/she doesn't do it right. The thin steel will just melt away and leave a bigger hole if the welder doesn't know what he is doing.

Patrick

Yes they can be welded, both of mine are, but like the quote above, use a good welder. The metal will burn away if too hot and then it gets ugly fast!

[Jerry]

When I had a similar problem opn my XJ, around the crossover pipe, the local shop brazed it instead of welding it.

[Bigfoot]

Has the brazing held up well? Might be a good option.

[XS1100 Newbie]

I pulled the exhaust off yesterday, and it is a mess. The muffler is completely broken off. Someone haywired it with a piece of pipe in it. The rear mount is all that really he would guess that i am in search of another left side muffler. I'll take it to the shop and see what they say, but i think it is kind of like resurecting the dead.

[Bigfoot]

They might be able to take a strip of metal or larger diameter pipe and weld everything back together, but it might not look to pretty. Finding a midnight exhaust, or even just muffler, is pretty tough.

[Jerry]

Has the brazing held up well? Might be a good option.

I replaced the stock exhaust with a Jardine system a few years back, but had the brazed mufflers on for a couple years and about 15K miles with no problems.

The opinion of the guy who did the work is that the brazing would add extra material to a spot that was prone to brakage due to corrosion or vibration. Since the brazing is primarily brass it does not corrode like steel and adds a layer of thickness to what is otherwise a mechanically weak joint. Polish it up and the brazing doesn't look to bad. Price would have been the same for either method.

[Bigfoot]

I have seen some that have been welded up and break right next to the weld in short order. Maybe you are on to something.

[XS1100 Newbie]

I have not done brazing for quite a while. I think i'll give it a try. I used to be pretty good at brazing.

[DiverRay]

Some of the "new" rod they use for TIG welders will do a GREAT job. The down side is the joint needs to be VERY clean for the brazing to hold. One little flaw and the joint is weak. I found this out in welding class, trying to braze together two CLEAN 1/4" steel bars.(class requirement)