1983 650 4 headers 2 into 1 muffler, mufflers corroded thru at side near end

[dennie]

I just bought a 650. The only item that need attention are the two mufflers which have corrosion right thru the side walls near  the ends.

Other than trying to locate a OEM replacement or aftermarket muffler can I attempt a repair?

I was thinking clean the corroded metal back to good metal, indent the edges in around the hole, make small steel sections to fit inside the hole and secure them with tiny pop rivets.  Then fill the depression with epoxy metal (Devcon), finish off the surface to match the muffler outside shape.  Then cover the repair with self adhesive metal foil

Any comments?
d

[floridahawk]

  Sounds like a lot of work for as patch job. I'd look on ebay for used one or new aftermarket. If You can"t find it after that I'd do the patch job. I'd would weld it or get someone to weld it though.  Good luck ! 

[ford141]

I'd have to agree on finding a used one.  Sound like a lot of work for a repair that might not last given the heat and vibration that the exhaust is subject to.

[haleland]

I had the same issue.  The metal was perfect except for where the baffel welds to the pipe.   I ended up cutting the  last 2" off and taking out the baffels. It looks cool but... I havent ran the bike with the modded pipes. I hope its not too loud.   I will let you know...

[drdubb]

I might have a couple of pipes. I've ordered some aftermarket, if I like them, I'll sell the stock, I don't, I'll sell the aftermarket. Can you wait a couple of weeks?

[medger]

Check out JCWhitney.com
They have universal mufflers from as low as $25 each. They also have some nicer ones if you want to spend a little more. I have not been able to locate a better deal even on ebay.