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Holes in my Mufflers..Recomentations on what to replace with

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    Holes in my Mufflers..Recomentations on what to replace with

    Recomentations....meant to be Recommendations.........Duh!

    Mufflers have some small holes and I prefer to replace than repair. Headers pipes, and crossover, right back to the mufflers are great. Want something that looks around the same or sounds the same. The only options i have found in NZ are Dunstall reverse cones, long and shorty's and Dunstall wide mouth re-packable's and a FD, (??), shorty.

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    FD shorty
    Last edited by 650Skull; 01-29-2021, 07:48 PM.
    82 GS650E (Canadian), 83 XS650SK (Canadian), Main machines Running
    Aussie, 74 TX650A, 80 XS650SG, 81XS650SH, 80XS850, in various states of repair/disrepair
    Introduction and ongoing thread for myGS650Ez
    Albums

    #2
    Where are your "small holes"? If they are at the bottom, right at the beginning of the muffler area, and about 2-3mm in size, they belong there.

    Those are drain holes for condensation.

    If you have holes anywhere else, it would depend on how much you want to spend and how tolerant you are of the looks. I have covered some sizeable holes in the middle of the muffler with a sheet of aluminum. I cut the sheet to overlap the holes at least an inch on all sides, then drilled holes around the edge of the sheet for rivets. After applying some muffler sealer/cement, I held the sheet up to the muffler and drilled the first hole in the muffler and installed the rivet. Now that the sheet is anchored, drill more holes along the upper edge of the sheet. When the whole side is anchored, wrap the sheet around the muffler, riveting as you go. You will soon have a reasonably-tight patch. Use a felt wheel in your electric drill to polish the aluminum sheet, most people will have to look twice to notice anything is "wrong".

    .
    sigpic
    mine: 2000 Honda GoldWing GL1500SE and 1980 GS850G'K' "Junior"
    hers: 1982 GS850GL - "Angel" and 1969 Suzuki T250 Scrambler
    #1 son: 1986 Yamaha Venture Royale 1300 and 1982 GS650GL "Rat Bagger"
    #2 son: 1980 GS1000G
    Family Portrait
    Siblings and Spouses
    Mom's first ride
    Want a copy of my valve adjust spreadsheet for your 2-valve per cylinder engine? Send me an e-mail request (not a PM)
    (Click on my username in the upper-left corner for e-mail info.)

    Comment


      #3
      Are these mufflers double skinned..........I guess the small drain holes would be for any moisture that collected from the headers...Headers being double walled.


      Right side

      Attached Files
      Last edited by 650Skull; 01-29-2021, 10:12 PM.
      82 GS650E (Canadian), 83 XS650SK (Canadian), Main machines Running
      Aussie, 74 TX650A, 80 XS650SG, 81XS650SH, 80XS850, in various states of repair/disrepair
      Introduction and ongoing thread for myGS650Ez
      Albums

      Comment


        #4
        Left side

        Attached Files
        Last edited by 650Skull; 01-29-2021, 10:13 PM.
        82 GS650E (Canadian), 83 XS650SK (Canadian), Main machines Running
        Aussie, 74 TX650A, 80 XS650SG, 81XS650SH, 80XS850, in various states of repair/disrepair
        Introduction and ongoing thread for myGS650Ez
        Albums

        Comment


          #5
          Full pic right
          Attached Files
          Last edited by 650Skull; 01-29-2021, 10:14 PM.
          82 GS650E (Canadian), 83 XS650SK (Canadian), Main machines Running
          Aussie, 74 TX650A, 80 XS650SG, 81XS650SH, 80XS850, in various states of repair/disrepair
          Introduction and ongoing thread for myGS650Ez
          Albums

          Comment


            #6
            I can't see any of these photos. Do the holes look rusty? Irregular shape? Or are they nice and round?
            sigpic
            '77 GS550B
            '78 GS550C

            Comment


              #7
              full pic left side
              Attached Files
              Last edited by 650Skull; 01-29-2021, 10:18 PM.
              82 GS650E (Canadian), 83 XS650SK (Canadian), Main machines Running
              Aussie, 74 TX650A, 80 XS650SG, 81XS650SH, 80XS850, in various states of repair/disrepair
              Introduction and ongoing thread for myGS650Ez
              Albums

              Comment


                #8
                Do other people see any large photos in posts #3,4,5,
                82 GS650E (Canadian), 83 XS650SK (Canadian), Main machines Running
                Aussie, 74 TX650A, 80 XS650SG, 81XS650SH, 80XS850, in various states of repair/disrepair
                Introduction and ongoing thread for myGS650Ez
                Albums

                Comment


                  #9
                  7 and 8 yes, 3 4 5 no.
                  2@ \'78 GS1000

                  Comment


                    #10
                    Sorry, about the disruptions guys and girls. Thought i had found a way to post full pics.........redone the attachments from my album.

                    My other question is..........do you think the mufflers i linked to, (post #1), sound OK on these bikes
                    Last edited by 650Skull; 01-29-2021, 10:24 PM.
                    82 GS650E (Canadian), 83 XS650SK (Canadian), Main machines Running
                    Aussie, 74 TX650A, 80 XS650SG, 81XS650SH, 80XS850, in various states of repair/disrepair
                    Introduction and ongoing thread for myGS650Ez
                    Albums

                    Comment


                      #11
                      Those holes are not the drain holes. The drain holes are closer to the swingarm pivot and would be smooth and round. Those are all a bit larger and irregular. If your ears are sensitive, you might hear the exhaust escaping, but shouldn't be too much louder.

                      I don't have any experience with the mufflers in your first post.

                      .
                      sigpic
                      mine: 2000 Honda GoldWing GL1500SE and 1980 GS850G'K' "Junior"
                      hers: 1982 GS850GL - "Angel" and 1969 Suzuki T250 Scrambler
                      #1 son: 1986 Yamaha Venture Royale 1300 and 1982 GS650GL "Rat Bagger"
                      #2 son: 1980 GS1000G
                      Family Portrait
                      Siblings and Spouses
                      Mom's first ride
                      Want a copy of my valve adjust spreadsheet for your 2-valve per cylinder engine? Send me an e-mail request (not a PM)
                      (Click on my username in the upper-left corner for e-mail info.)

                      Comment


                        #12
                        You can use hose clamps to hold the sheet metal in place while drilling and riveting. Best results are achieved by drilling, then removing to debur the holes. Add the muffler cement and reinstall using hose clamps to get a nice tight fit.
                        1981 GS 1000GLX.
                        1981 GS 1000G.
                        1981 GS 650GLX.
                        1975 TS 185.
                        1972 100. Kawasaki.
                        1968 100. Suzuki.
                        1970 Z 50. Honda.
                        1984 CT 70. Honda. (Kids)
                        1982 DS 50. Suzuki. (Kids)

                        Comment


                          #13
                          Also, there is a LOT of discussion on this forum (use the search function) for members asking others for advise on muffler replacement. Check especially the CARB/FUEL/EXHAUST board.
                          Last edited by xkaes; 01-30-2021, 09:42 AM.
                          sigpic
                          '77 GS550B
                          '78 GS550C

                          Comment


                            #14
                            Originally posted by habsdoc View Post
                            You can use hose clamps to hold the sheet metal in place while drilling and riveting. Best results are achieved by drilling, then removing to debur the holes. Add the muffler cement and reinstall using hose clamps to get a nice tight fit.
                            If i wanted to repair them i would.......Asking if anyone had used the type of mufflers in the links and any thoughts on them
                            82 GS650E (Canadian), 83 XS650SK (Canadian), Main machines Running
                            Aussie, 74 TX650A, 80 XS650SG, 81XS650SH, 80XS850, in various states of repair/disrepair
                            Introduction and ongoing thread for myGS650Ez
                            Albums

                            Comment


                              #15
                              Originally posted by Steve View Post
                              Those holes are not the drain holes. The drain holes are closer to the swingarm pivot and would be smooth and round. Those are all a bit larger and irregular. If your ears are sensitive, you might hear the exhaust escaping, but shouldn't be too much louder.

                              I don't have any experience with the mufflers in your first post.

                              .
                              Good to know that there were drain holes...........Knew it was rust and in the early stages but in my situation i thought i would like to replace. Not a lot of options in NZ and i spent hours looking. Thanks steve
                              82 GS650E (Canadian), 83 XS650SK (Canadian), Main machines Running
                              Aussie, 74 TX650A, 80 XS650SG, 81XS650SH, 80XS850, in various states of repair/disrepair
                              Introduction and ongoing thread for myGS650Ez
                              Albums

                              Comment

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