Fix Hole In Muffler, How?

Discussion in 'Technical Help' started by TraiaRider, Mar 6, 2025.

  1. TraiaRider

    TraiaRider New Member

    Aug 4, 2024
    1
    3
    Sweden
    If anyone could give me some pointers on how to fix a hole in one of
    my mufflers the best way possible,
    I would be most gratefull!

    The hole is facing downwards and is not visible so even a quick and dirty fix solution would be somewhat OK.

    JBWeld or actual welding and if so
    is it best done with a TIG-weld?

    see image below.

    I drive a Triumph Bonneville 2001.

    Best Regards

    Ola

    20250306_174426.jpg
     
    • Like Like x 1
  2. joe mc donald

    Subscriber

    Dec 26, 2014
    14,673
    1,000
    slough / burnham
    @TraiaRider I fear that is not a repairable hole i do think the whole can is ready to fall to pieces. I have a set of cans in my garage and if i could see more of yours i could try and match them. And i know its a distance to you but if they fitted and you wanted to pay postage they are yours.
     
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    • Agree Agree x 1
  3. Jamesian21

    Jamesian21 Member

    Apr 15, 2024
    37
    18
    Texas
    You can get used oem mufflers on ebay for less than $200.. do NOT repair that. Replacing would be easier and better for you in the long run
     
    • Agree Agree x 4
  4. Eldon

    Eldon Elite Member

    Nov 14, 2018
    6,693
    800
    North Yorkshire
    I've welded many new and old exhausts and as @joe mc donald said that looks too far gone to be worth the time or effort.

    Often the damage is much further reaching than what is initially apparent.
    Bin I'm afraid, or a good template for a new build.
     
    • Like Like x 1
  5. Pegscraper

    Pegscraper Elite Member

    Jun 12, 2020
    3,416
    800
    Yorkshire
    I doubt Paul Daniels could have fixed that. The rest of the can is probably wafer thin.
     
    • Like Like x 1
  6. TraiaRider

    TraiaRider New Member

    Aug 4, 2024
    1
    3
    Sweden
    I think the hole is caused by water standing inside the exhaust pipe.
    The rest of the pipe seems pretty solid but I will check again. The other pipe of the pair is perfectly fine.

    I dont know what its called but it is the Triumphs own racing variant with the text "Not for road use" stamped on the side. My original pipes are fine.

    Do you have the racing ones for sale? I will post some pictures
    of the whole pipe.

    Can you find them on ebay?

    I think Triumph stopped selling them.

    I saw some one even made a fix with pop rivets and JBweld :grinning:

    Thank you for replies
     
  7. TraiaRider

    TraiaRider New Member

    Aug 4, 2024
    1
    3
    Sweden
    Here comes some more pictures.

    The image with the stamped text says Triumph 9601023 at the top.

    20250317_181432.jpg

    20250317_181542.jpg
     
  8. TraiaRider

    TraiaRider New Member

    Aug 4, 2024
    1
    3
    Sweden
    The pipe seems sturdy except for just around the hole. It is not paper thin.
     
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