Exhaust / Muffler hole

I have this hole at the base of the right-side silencer on my XJ750 SECA. It appears that there had been a previous repair with some sort of expoxy or similar. With my recent rides, it must have blown out.

I was considering patching the hole with JB Weld Extreme Heat Metallic paste (basically Exhaust putty). In probing around, I found an internal pipe completely rusted free inside.



It can move back and forth and rotate, so it is completely loose inside.
The rest of the exhaust and muffler appear in good condition, although I suspect there is a good possibility that other sections are rusted as well.

What are my options?

• Leave it and repair the hole with the JB Weld? I suspect this may leave an annoying rattle unless I can secure the pipe somehow.
• Remove the exhaust silencer and pull the internal pipe out? Will I even be able to remove it? Then repair with JB Weld? What function does the internal pipe serve? Is this the actual exhaust with the chrome outer for appearance and to insulate from the exhaust heat?
• Remove exhaust and somehow repair/replace the internal pipe? I would likely have to take to a shop as I do not have welding skills or equipment.
• Other?

My original plan was to cover the patch with metal exhaust tape or for a better option, put on a chrome exhaust clamp to cover the patch.

 

1 replace whole muffler
weld a patch but that location looks iffy for that
no jb weld has no retention strenth and will blow out auto parts store has muffler bandage you can wrap around and it cures with heat

replacement is best option

 

I was afraid someone was going to say that.
Options for replacing? I kind of perused the bay and did not find much in decent condition without scrapes, dents, rust etc. Anyone know of aftermarket replacements that remain true to the original appearance and function?

As part of my original repair plan, I was going to somehow put in some metal screen internally to help give the JB-Weld something to hold on to.

How critical is this to performance or operation? If not, I can live with it for awhile, as I have other areas on the bike to spend money and time.

 

I have a MAC 4 into 2 on my Seca ...po put it on seems like a good system . Can't say what price is. Agree with XJ550H replace not worth trying to "fix"

 

I don't think you will like it if you weld it or if you patch it. I don't even know how much is there to attach to? Once you get that band loosened up and slid of that part, it might be rusty all the way through that part as well. Meaning that might not be anything left under that band to hold a weld or jb weld. You would have to make a patch and then MIG or TIG it in there, grind down the weld and then I guess paint to make it look good.

Your call.

 

keep your eye out for a set of stock harley mufflers

 

Harley mufflers would work???? If that's seriously the case Ive got a set off a 2013 883 super low sportster I'd sell. Wife wanted to upgrade to a stage 1 kit on her Harley so I've got the mufflers and an air cleaner lying about now

 

Not really concerned with appearance at this point. It is down low, partly hidden under the middle exhaust collector shield. The hole is between the size of a nickel and a quarter, but you're right, it does appear to be cracked, rusted all the way around. If I take things apart, it would likely break apart there instead of coming out of the middle exhaust section, where it is probably fused.

Hmm. Marving has a set of silencers for about $360 USD inc shipping. MAC has a full 4-2 exhaust for just under $500.
I noticed the MAC system doesn't have the same collector setup, no crossover. Do you think this will affect the jetting or breathing of the carbs in any way?
Would Harley mufflers require any mods to attach? What about the little stop that the center stand rests against on the underside of the left muffler?

If this is a cosmetic issue only, I will probably wait. If it is a performance issue, it will just be added to "The List". If I can get by with wrapping in metal exhaust tape and/or patching, even if I have to replace every so often, I will probably go that route and do the best I can to minimize the repair. Maybe cover the repair with something like this?

This isn't a show bike.

 

MAC claims you can run their 4-2 system without re jetting, I don't know for sure but if that is the case I'm thinking about going the same route on my 650 Maxim. The Harley mufflers require a little bit of cutting and possibly welding on some extra tube so they have a good area to clamp on to, you'd also probably have to move or make brackets and tack them on. I can't imagine that hole is doing the exhaust system any good and the longer it's there the more it will rust out, I'd start working on it pretty quick

 

I have "something like that" on mine right now. Small section of stainless steel shim stock and a couple hose clamps. If ^^^ that isn't too expensive get it... I had quite the wrestling match getting that stainless to curl around the pipe.

 

The Mac exhaust bolts right on like stock , has a nice sound too. On my Seca I went up from 120 to 124 and I think to a 41 .. I'm not sure I needed to do it at all.