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Old 01-22-2015, 06:15 PM   #1
bentmettle OP
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Cracked Gas Gas muffler

I don't want to be "that guy", but I want to engage the fine community here and I have some questions before summer comes and I start re-ignoring maintenance

2005 Gas Gas 300 TXT. Overall in good shape.

Just noticed that the muffler has a crack in it.




I assume this isn't completely out of the ordinary given that there is a huge hole right there for the crack to grow from.

Anything I should do with this besides TIG it back up?
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Old 01-22-2015, 07:42 PM   #2
lineaway
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Usually the mid pipe breaks first. Tig it.
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Old 01-22-2015, 07:45 PM   #3
brewtus
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Quote:
Originally Posted by lineaway View Post
Usually the mid pipe breaks first. Tig it.

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Old 01-22-2015, 07:47 PM   #4
DerViking
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As "that guy" who put a piston in backwards, what can I say?

If you can weld aluminum, than have at. It's non structural, if it fails you won't get hurt.
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Old 01-22-2015, 07:55 PM   #5
bentmettle OP
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Quote:
Originally Posted by lineaway View Post
Usually the mid pipe breaks first. Tig it.


I suppose this bead on the left rear side does look like a field repair now that I look closer and see the wire brush marks on it.
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Old Yesterday, 07:52 AM   #6
motobene
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When you reassemble you can seal the interface with clear silicone seal. That will increase structural strength so less likely to crack again. And later you can get it apart because it is a rubber. Silicone also seal things well to prevent dripping mung or spraying spoo.

I have this custom titanium header on my bike that works awesome, but wasn't made perfectly. The flange at cylinder end is warped and won't seal without assembly with silicone on both sides. The other end comes up short, barely into the first o-ring in the muffler.

Silicone seals the cylinder interface, and holds the other end in the center muffler. After a year and a half of joy, I recently smacked a log hard and broke the seal. I could hear the exhaust more and go mung seeping out of the exhaust port area. Boo!

I removed the pipe and rolled the silicone off with my thumb at the cylinder flange end of the pipe. I removed the stuff on the other end with a wire wheel. Re sealed carefully and now it's back to new.

Silicone 1 RTV is a wonder substance.
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Old Yesterday, 02:16 PM   #7
bentmettle OP
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thanks for the suggestion. I may give that a go when it warms up.

I braved the frozen garage to zap it back together.

I am a horrible hack with aluminum!
I struggle with heat control at the edge of sheet metal like that, especially in a butt weld scenario.



But it's more or less fixed for the time being.
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Old Today, 08:06 AM   #8
motobene
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Quote:
Originally Posted by bentmettle View Post
thanks for the suggestion. I may give that a go when it warms up.

I braved the frozen garage to zap it back together.

I am a horrible hack with aluminum!
I struggle with heat control at the edge of sheet metal like that, especially in a butt weld scenario.



But it's more or less fixed for the time being.
Handling aluminum parts in the cold is

As a long-time TIG welder, don't be embarrassed by your job at all! All those nice aluminum welds you see are under very controlled, repeat circumstances. I never get super nice welds on one-off repairs. One nice thing about really cold thinner aluminum parts, however, is they are less likely to blow out when welding.
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