muffler cover

[John Bates]

I am refurbishing  my exhaust system and would like to replace the muffler cover.  The shiny metal cover is scratched and dented and the muffler underneath is dented.  So it looks like the best way to fix it is to replace it. Has anyone done this or something like it? :dunno:

Or maybe a heat shield of some type?  It wouldn't necessarily have to wrap completely around the muffler to hide the dents.

I'll bet Srinath has done something like this!! :mrgreen:

[The Buddha]

Yes I have ... I have hacked it off and tossed it in the dumpster. wny would I even bother fixing that POS ...
Cool.
Srinath.

[John Bates]

Yes I have ... I have hacked it off and tossed it in the dumpster. wny would I even bother fixing that POS ...
Cool.
Srinath.

So how did you fix/cover-up the dents in the muffler? :dunno:

[The Buddha]

Not a clue ... of course there is the obvious swap it for a good muffler and weld it in idea ...
Cool.
Srinath.

[500rider]

You can buy stock mufflers off eBay for like $20.  You could convert a stock SV650 or GSXR600 muffler to fit your exhaust.  Some people have done it on the forum.  I haven't but people have done it.  It would not likely be much more work than fabricating some kind of cover for your stock muffler.

[dgyver]

I have thought about making a carbon fiber cover for the stock exhaust. It would just snap over the can, basically the same size as the stock chrome cover.

[stefman722]

I have thought about making a carbon fiber cover for the stock exhaust. It would just snap over the can, basically the same size as the stock chrome cover.

Make one. Id buy it.

[gerharddvs]

You can buy stock mufflers off eBay for like $20.  You could convert a stock SV650 or GSXR600 muffler to fit your exhaust.  Some people have done it on the forum.  I haven't but people have done it.  It would not likely be much more work than fabricating some kind of cover for your stock muffler.

Where on EBay were you getting one for $20 and was it complete or just the cover, also looking for nice one

[weaselnoze]

who wants it? a dent in the back and cover is basically good.  btw bates, new avatar  

[Jared]

Is this sort of what you're looking for ?

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1&item=4522000020&category=35596

[gerharddvs]

who wants it? a dent in the back and cover is basically good.  btw bates, new avatar  

Almost in same condition as mine Only differince, I have a little ding on right the edge of the cover.

[gerharddvs]

Is this sort of what you're looking for ?

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1&item=4522000020&category=35596

Yes but can you and how do you remove the old cover and also how do you fit the new one since it seems to be rivited to the pipe

[Jared]

You don't remove the old one. This clamps over the whole can ( Thats for an ex500 in that  auction...I don't know if they even make these things anymore...I KNOW I saw them somewhere in a catalog but it was a while ago.)

I assumme if they were made to fit a certain bike they just cover the whole  can or most of the can....

I do remember a universal one somewhere tho... I'll dig it up if i can.

[500rider]

Where on EBay were you getting one for $20 and was it complete or just the cover, also looking for nice one

I have seen them on eBay previously.  I don't know if there are any right now.  Usually there are up for auction because someone bought a performance exhaust for their bike and don't know what to do with the old one.  They figure they'll recover the cost by selling on eBay.  They usually go cheap though because no-one else wants 'em either.  I've seen complete exhaust systems go for $20.

[John Bates]

Thanks for all your suggestions folks.

My son Jason and I reviewed our options and decided to replace the cover. 
We felt we could do it without much trouble. 
Here's what we did:

Drilled out the rivets on the one edge and cut along the
weld of the welded edge leaving a narrow welded strip attached.

Spot welded strips around the circumference at each end and the middle.
The same thickness as the original cover.

Cut a piece of 4 inch diameter stove pipe to the length of the original cover. 
Using the original cover as a pattern cut the necessary notches and radius'.

Did some sandblasting and powder coating, riveted it together and walla,
a new exhaust system.

That's an antique silver finish on the cover.

Here's some before and after pics.

[Kerry]

Bee-yoo-tee-ful!  

[JetSwing]

[weaselnoze]

thats the ultimate restoration exhaust!  nice work, and its original too