Drilled muffler

Previous owner drilled a series of 3/8 holes in the end of my mufflers. I am trying to come up with a way to reverse that modification. I thought about a large blind rivet but I cant find anything that big. Any thoughts?

 

You could use Stainless allen head bolts with nuts and lock washers on the inside. But you would have to remove the baffle first of course.

 

A couple of ideas. JB Weld should hold well if you can clean the area. Also there is a 2 part putty epoxy that is used for muffler repair that would work. Either one can be ground smooth after curing then painted with high temp paint if you desire. The repair should disappear.

 

use a large self tapping screw........

 

welder

 

Just anything larger than the hole itself, +1 for ease of doing it

 

cut some aluminum or stainless to fit and rivet it on. It will take some work but would look nice. even thin aluninum flashing polished up would look good. muffler cement between to keep things selaed up.

 

thanks for the replies. I have never seen a self tapping screw 3/8 diameter. I doubt I could close the holes with JB weld without getting a pint or so inside the muffler. I guess I could cut a disk to cover all of them like 85Max suggest but it is not a simple circle so I was hoping for and easier out. Anyone know the diameter of an automotive power window rivet ? That is the largest blind rivet I know of. Thanks again all.

 

If it need to be pretty ... cut-out a sheet metal cover and rivet it in place, sealing it up with some JB Weld using a Popsicle Stick to make the contour rounded along the outside diameter.

If you just want to block-up the holes and be done with it ...
Molly Screws and Fender washers.

The Molly Screws fit in through the holes and expand on the inside as you tighten them down.

 

I thought about toggle bolts but mollys never entered my mind. That may be the way to go. I am just trying to get the bike stock again. (The way I remember it it 1981). It is louder than it should be. I know some guys want that but not me. I am not anal about the way the muffler end looks although I agree that a plate of some kind would be prettier. Thanks Rick

 

eBay yourself a set of stock mufflers. Maxim easier than Seca, might take you a month, if that. Took me two months (approx) to locate all the components to put a stock system back on mine. And it's a Seca...

 

What kind of bike is this for? I have the dual exhaust for an '82 XJ650 without the header pipes. They cost me $60 bucks. Cover that & shipping and you can have 'em. I ended up going with a single pipe exhaust and have no use for them. Let me know.

 

if all you need is something to cover 3/8", i would go with the pop rivet. we have several different varieties at our shop, some with heads that are 3/4". you would need to get the butterfly style so it wont pull through the hole. or just use some bolts and stick them in, and tack weld the heads to the end cap.

 

The mufflers are in perfect shape but thanks for the offer. Pop rivets are what I had planned but I could not find anything that would mushroom out to hold in a 3/8 hole. I will search for butterfly type. thanks

 

Would there be another term for "butterfly type" pop rivets ?

 

Any luck on this, usehername? I'm in the same boat with my '82 750. PO drilled three 3/8's holes on each pipe. Granted, I'd love to replace them as they are nice and brown up front, but a quick fix would do for now.

 

"tri-grip" i saw them described as, on a site that didnt sell them..... :roll:

here is a pic of what they would do....the one on the right. they have a very long body, that is perforated, and when the mandrel pulls in the body splits into 3 "wings" that fold out, rather than the body just mushrooming a little.