Ideas for repairing muffler mount?

[Clutch]

Hey all,

I think this is a common problem, but my chrome muffler housing has cracked around the mounting brackets that get bolted to the frame. My right side bracket has completely broken away and taken a small part of the muffler with it. I've been riding this way for several years, so it isn't a huge deal. The biggest aggravation for me is that when the muffler vibrates, it often rubs against the separated piece still attached to the bracket and makes a loud squeaking sound. I am hoping someone has a good idea how I can mend this problem.

Otherwise, I may bite the bullet and get some replacement mufflers. If I choose to go the new muffler route, anyone have suggestions for decent replacements? I know of the OEMs, and Mac whispertones... any other options out there? Any opinions/comparisons of the whispertones to OEMs?

Thanks!

[Luca]

If you or a friend have a welder, just weld the bracket back into place.  You could also go to a welding shop and probably have them do it for short money.

The weld will probably hurt the chrome finish and will surely rust quickly, but it should last for years before it's a problem again.

[Tony Smith]

If I choose to go the new muffler route, anyone have suggestions for decent replacements?

http://www.staintune.com.au

Yes they are expensive, My R100 has won a set since about 1982, my wife's R65/80 since about then as well and my 1985  R65 project also has a set - aside from a bit of age related patina and the odd bit of mechanical harm, they are all as good as the day the were fitted.
 
Buy once, use forever.

[montmil]

If you don't wish to spent a lot of cash on a replacement muffler, EMGO -that's Made in China spelled backwards- has these Norton Peashooter repops for around $150 the pair. Header pipe inlet matches the R65 w/o any adapter rings. Been on the '83 for a few years and holding up quite well. Great sounds, too. Not too loud but just roarty enough to sound sporty. EMGO also produces a BMW repop muffler.



I have the same "Peashooter" muffs on the '81 R65 but they are the EPCO stainle$$ bits.

[Clutch]

If you or a friend have a welder, just weld the bracket back into place.  You could also go to a welding shop and probably have them do it for short money.

The weld will probably hurt the chrome finish and will surely rust quickly, but it should last for years before it's a problem again.

So I was wondering about this option... you think it is possible to weld it back together? I'd have to bring it to a local shop to have it done, but it should be doable?

[Tony Smith]

If you or a friend have a welder, just weld the bracket back into place.  You could also go to a welding shop and probably have them do it for short money.

The weld will probably hurt the chrome finish and will surely rust quickly, but it should last for years before it's a problem again.

So I was wondering about this option... you think it is possible to weld it back together? I'd have to bring it to a local shop to have it done, but it should be doable?

It isn't really. The mount is welded to an internal "frame" inside the muffler. to do the job properly you would have to cut the muffler open, repair the frame, weld the external mount to the frame and then weld a patch onto the outer casing.
 
All of which is possible, but would cost about what a new pair of cheap Chinese mufflers would cost anyway and would like a bit Frankenstein-ish.

[Clutch]

So, another ignorant question... do these aftermarket mufflers' mounts always line up with the spots on the bike frame?

[Justin B.]

Try your local Junior/Community College.  I remember when I was taking some machining and welding classes folks would bring stuff by all the time and the instructor would supervise some of the students in the welding.  I don't ever remember there being money changing hands as it was considered good practice...

[ShutterPilot]

Hi,

I'll attest right now that 1. Yes, the muffler mount areas can be welded and 2. They can be done so neatly, cleanly and be structurally sound. Just had both the left and right Zeuna's done locally by a true welding guru. Secret is getting all the carbon cleaned up properly.
No burns, spits - and the welds were so flat and seamless, they mounted right back up with no additional augmentation needed at either the frame bracket or muffler mount point.
Total price? $80 for the right (split repaired at header slip point also) and $50 for the left.
As I needed to keep the stock Zeuna's for a race class, money well spent.