Muffler hole.

[JAS6377]

So, I just noticed this today, which is odd. But it explains the clunk that I've heard over bumps.



It seems as though my muffler bracket bent and allowed the nut from the caliper to rub a hole in my muffler.

Onward to fixing. Obviously the ideal approach would be to get a new muffler from Jardine. But I don't have the funds for that, as I just bought a new battery, and will need a new rear tire later this month. Any ideas from the frugal backyard mechanics? I'm thinking exhaust wrap, but I don't know if I should fill/cover that hole first.

Feel free to flame on, as I'm kicking myself in the ass anyway for not noticing it sooner.

[fetor56]

Temp fix.....Cut a patch of thin metal(eg,aluminium or steel from a coffee can) and JB weld it there.
Just might surprise u though how these temp fixs become permanent. 

[Big Rich]

+1.

What is the muffler material? Stainless? If so, scuff up the surrounding area with some rough sandpaper to give the JB weld something to grip to. Once you put a patch on there, wrap around the entire diameter with some kind of tape to hold it while the JB weld cures.

[AnonRider]

lol, same thing happened to me. i just bought a slip on muffler from delkevic and called it a day.

[JAS6377]

I thought about doing the JB Weld, but then I found this:



It's a steel reinforced epoxy good for 1000 F, and it specifically states mufflers and exhaust for uses! After application, some grinding, and using a wire brush, my muffler now looks like this:



It is a stainless can, so I'm thinking about galvanizing it and then covering it with aluminum tape. But for now, it should hold.

[Watcher]

Since its on the inside edge, I wouldnt even worry about covering it up if you are doing it because it looks bad.  You likely won't see it anyway.

But the easiest approach would be to paint it.  They make high temp paint in silver, even if it doesn't match 100% I don't think you'd be able to tell once its mounted.

[JAS6377]

I'll have to look into that. I tend to be a perfectionist. While others may not notice it, and I won't see it while riding, I'll always know it's there. And it'll haunt me until I fix it lol.