Exhaust repairs

[Jonesy]

Dunno about you Brett but I like to use oxy/acet on thin stuff. Sort of like a slow burn compared to an instant wack from arc weld

ya done good but

[XSNT999]

Jeez Brett, you're a braver man than me Gungadin.

It's been many years since I've done any welding, but even back then I doubt I would have attempted this job, the pipes looked long gone.  If you've managed to fix the pipes to a stisfactory condition, then well done.

Cheers

[BrettS]

For those don't weld, this is why I run a mile when my mates pull the car up in the driveway and ask if I can pull the welder up and weld a small hole in the exhaust 

That last picture of the rust on the pipe turns into this,

Even then you are often welding into steel that is degraded and that causes all soughts of welding issues.

On the left of the above pic is a little pin hole that I hoped to just weld up, it worked same spot other side but this area just disintegrated and this is the real damage that was hidden under paper thin steel.

The crack turned into this which was not to bad, but was the repair I most feared causing trouble. 

I wanted to fill this hole with weld which could have turned into a disaster but I managed to bridge it without leaving any obstruction inside the pipe.


This shows how thin the steel is. Even a light tack will often blow through.

I am happy with how it turned out, should get another 5-10 years out of this set unless I hit a rock or something and it slices through the paper thin steel 
Obviously not worth chroming so I think I will put some of the very fashionable exhaust wrap on. Found some good info on that
http://www.allaboutbikes.com/feature-articles/motorcycle-maintenance/6963-unwrapping-the-mystery-of-exhaust-wrap

[BrettS]

Last time I took the exhaust off I had ordered a new set of gaskets but when I took them off I thought my exhaust had none? A recent trip with Jonesy out to Carls Engines and Carl noticed the exhaust was leaking and told me yes they do need gaskets   

Just took them off again, this time I looked into the engine exhaust with a torch and I see the old gaskets there. Checked the gasket to the exhaust and see they just fit as per normal. Oh I am an idiot sometimes.

I decided to go over the exhaust a bit better as well. I had suspicions that there was a slight leak or two on the pipes and was not sure how well the muffler fitment was as it was quite loose.
As soon as I took the pipes off I saw a crack and definite leak point, not sure that was there last time. So since I am pulling the welder out I better go right over them. It seems it has been repaired before and there are several spots that will need filling or patching.
This exhaust seems to work very well, with no lagging through the range, so I figure I should work at keeping this one.
The muffler seems in good nick and should clean up ok. At the moment it just slips on the pipe. It was not easy to force off but once in place it does seem to have some room to move and will flop around a little. Once bolted to the bike it sits nice and tight but I wonder if I should find a way to secure it to the pipe and make sure it can't leak ? Any ideas on how to make it leak proof, can't really weld alloy to steel.
I have added a picture of the gaskets so anyone can get the updated part number to order.
Oh and I am liking the idea/look of the exhaust wrap they are using can some one tell me what that stuff is.
Thought i should show you a picture of my gragae LOL