The band clamp fix worked at first, but it kept coming loose—that’s no good.
Time to improve it.
I got some material from a famous muffler craftsman the other day for spring hooks, so I bent and made them.
I stripped the paint and welded hooks at six spots.
I gave it a light rust-preventive black coat.
I bent a flat bar on a three-roll bender and attached a stopper. Now with the spring plus stopper, it shouldn’t move at all.
I ground down the broken end to reuse it and prepped it for welding.
Welding the perforated section directly would cause it to break, so I welded a pipe first and then slipped the perforated section over it.
Some expert said that pulse welding beads lack a certain “character.” I have to agree.
First I did a light fit check.
Then I tack-welded about sixteen spots to hold it in place.
A straight pipe would be too loud, so I’m making it gentler on my own. I punched out the perforations with a die.
Getting it as tight as possible makes the welding smooth.
I welded it together wherever I could.
I don’t have fiberglass wool on hand, so I made a dash over to the nearby motorcycle shop.
That place is so convenient.
And by chance, the size I bought was a perfect fit—couldn’t have been better.
Then I gently inserted it and fixed it with rivets—done.
For the spring, I used my favorite soft Yoshimura one plus a shrink tube.
The sound is now gentler and we’re all set.
