Tailpipe repair

Hi Guys,

My XJ900 has an old 4 into 1 exhaust set up. The tailpipe section containing the exhaust baffle (sort of a piece of pipe with strategically placed holes along it and over which I have wrapped a small amount of fibreglass baffle material) has an end cap which seals the tailpipe but it also is a moutning point for the internal baffle.

The end plate is old and rusted on the inside and is no longer supporting the baffle, allowing the baffle to rattle around inside the tailpipe. Thought my engine was falling to bits before I located the source of this!!!

Anyone with a handy hint on what I can use to fashion an end plate - the tailpipe is quite small in diameter compared to a lot of exhaust setups today - I reckon it is only around 4" to 4.5" in diameter.

Thanks.

 

Sounds like it's time for a new muffler.

 

Or, pull the guts out of it and make the neighbors mad.

 

It is tough to get a good patch on these mufflers, as it either makes a lumpy discolored mess, or you make new holes, or the patch falls out. I am a crappy welder though, so if you get it to work, then go for it.

My worst hillbilly exhaust fix was on my KZ750, the middle communicating pipe for the dual exhaust was rusted out so I hacksawed the remainder off and plugged the hole with JB Weld and stuck the woman's tea ball over it and wired it shut. Those are the little balls with holes in them that loose tea leaves are in for hot tea.

That fix lasted three years, even though it was a roadside temp. fix.

 

You can also patch exhaust sytems with fiberglas. The hotter it gets, the harder it gets. I've patched mufflers many time with it and it works. You can sand it and paint it with high heat paint when it cures. I patched an old canister muffler (4 into 1 setup) on my old 550 Honda and painted it black. It looked like it was made that way! Or you can leave rough and it looks like carbon fiber when you paint it. >PD<