Muffler Hack

[HalfCentury]

As promised, here is what I have done. The muffler is cracked 95% around the circumference where the side stand rests near the muffler. My guess is a mishap with the PO.

The can is a 29 ounce tomato puree can. I cut out a rectangle to allow two sides to go past the pipe that connects the two sides.

Clamps are stainless Lowes $2 each. The muffler would probably fall off if not mounted. It really needs a good welding job. The entire exhaust system is surprisingly almost entirely rust-free. The crack is a shame.

[kboehringer]

Welding Mufflers

It really needs a good welding job.

HalfCentury,
You mentioned the mufflers are surprisingly rust free but I would suspect they are not on the inside.

I've taken apart, cut, welded and ATTEMPTED repairs on these OEM XJ/XS mufflers SEVERAL times and found they are rusty as heck on the inside. If the muffler was "CRACKED" it had to be the result of severe stress and/or RUST on the inside. The OEM Yamaha exterior casing is very thin when it's brand new and could be a bit of a bear to weld NEW. After years of use and rust they are absolutely IMPOSSIBLE to weld. There's just not enough "MEAT" left there. A tap of the MIG or TIG on the lowest power setting and you'll blow a hole the size of a dime in the muffler.... NO KIDDING.

IN MY PERSONAL OPINION. Unless you can find a set of OEM mufflers off a bike that was BARELY driven, and stored in a beautiful climate controlled environment it's not worth even buying ANY other used set. They're ALL 35+ years old.

I've free access to much better welding equipment than most, access to professionals with years of experience to point me in the right direction(s) when I need help, and some pretty good personal welding skills. I won't attempt to weld a 35 year old OEM Yamaha muffler again always a total mess and a waste of time.

KURT

[HalfCentury]

Points taken. I will not try to have the muffler crack welded.

Below is a pic of the entire muffler. It is dirty and smudged but zero rust. It should clean up and shine with some elbow grease this spring.

[CatatonicBug]

I've welded (MIG) my MNS exhaust a few times. Cracked in the same place. Yes, the walls are thin, and the end welds aren't pretty, but I have no issues with the welder blowing holes in them. Maybe there's a difference between the shiny chrome and the black chrome, but I'd MUCH rather weld the crack than look at a tomato can on my pipes.

[kboehringer]

..SNIP..the end welds aren't pretty, but I have no issues with the welder blowing holes in them. SNIP .

CatonicBug,
I beg to differ with you. The end welds aren't pretty because you can't introduce enough heat to actually get the metal to FLOW and make an actual "WELDING" of the filler metal with the surrounding existing metal. A bubble of molten metal stuck on top of the crack is not a "welded" repair.
Very respectfully,
KURT

[CatatonicBug]

Ok, it may not be a "proper" weld, but it stays put and doesn't re-crack. To me, that's "welded". I was able to add layers of weld to build up the edges, and increase the strength of the surrounding metal, and fill in the rusted out holes at the same time.

[tomcos67]

Points taken. I will not try to have the muffler crack welded.

Below is a pic of the entire muffler. It is dirty and smudged but zero rust. It should clean up and shine with some elbow grease this spring.

Put one on the other side, Bam done.!!!.💡

[HalfCentury]

Put one on the other side, Bam done.!!!.💡

That is funny. Thanks.

[HalfCentury]

I've welded (MIG) my MNS exhaust a few times. Cracked in the same place. Yes, the walls are thin, and the end welds aren't pretty, but I have no issues with the welder blowing holes in them. Maybe there's a difference between the shiny chrome and the black chrome, but I'd MUCH rather weld the crack than look at a tomato can on my pipes.

I don't own a welder, no training welding, and don't know anyone who does, so, tomato can will allow me to ride until I can find a better solution.

I passed up a parts bike that I should have bought. It would have been a pain to pick up and bring home. There were actually multiple parts bikes within a state or two away this past fall.

When the collector/connector pipe rusts away underneath, it will be time to have a solution. In the meantime, I love to ride this bike.

[Jerry]

I found a shop, back in the day, that brazed cracks in exhaust systems instead of welding them. JAT.

[HalfCentury]

I found a shop, back in the day, that brazed cracks in exhaust systems instead of welding them. JAT.

Thanks. I will look for a brazing shop nearby.

I checked out your gallery. Do you have a picture of your Vetter saddlebag brackets mounted to your XJ without the saddlebags installed? I will be trying to mount a non-XJ bracket to my XJ soon.

[red bandit]

The tomato can fix only matters to you. Do what you want. Enjoy the ride.

[webbcraft2150]

Here's what I see. It not a tomato can hack. It is a carefully engineered exhaust heat sink device that will cool the exhaust stream down, resulting in a reciprocal scavenging effect of the exhaust. This will result in a substantial velocity change of the exhaust, resulting in a measurable increase in rear wheel horsepower Now the question is, do you rejet and run 20-50 oil and change to either Metzlers or Dunlops? I see the need for a high performance clutch cable very soon.


The hack actually looks pretty good considering the materials.

[mikubuilder]

I've welded my exhaust extensively , I think I've posted some of the picks, as some members were interested how the exhaust is designed on the inside....it still holds, three years later.

Careful TIG, Stainless patches, all good