Repair of Holes in End of Exhaust

I want to fill in some holes that were drilled in the end of a stock exhaust tail. Would JB Weld be the best for fixing this? If so, can I just use it like wood putty, filling in the holes and smoothing (grinding) after it cures? Or would I need to cut a thin sheet of metal to fit over the holes? Or do I need something else completely?

Post edited by: bemoore, at: 2007/10/22 08:30

you are going to need to try to have it welded, the heat cycles are going to prevent epoxys from working, the down side is the rust may prevent it form being welded

If bonding material and welding don't end up working, have you thought of stainless steal screws? You would want to use stainless steal star washers for sure... preferable ones with the locking tabs on the outside circumference of the washer.

I have not tried this myself so I can't guarantee the results. Have any other members here done something similar or see any problems with this solution.

Best of success!

Post edited by: bill_wilcox100, at: 2007/10/22 10:43

Post edited by: bill_wilcox100, at: 2007/10/22 10:48

del

I saw some really big washers at a farm and home store that look like they might cover them holes. Maybe get lucky and they'll have the right size. Then just pop rivet it in place.

I would wire wheel the rust off and JB Weld a washer on there. The epoxy will sag around the inside of the holes, locking the washer on. I think the heat that far back is a non-issue, JB Weld claims heat resistance to 500 degrees. If the pipe gets that hot, move your feet to escape the molten engine. :laugh:

I've used JB Weld to patch holes on the end of my muffler, using stainless steel sheet metal patches. Some patches fell off, I believe due to not roughing up the backside. I roughed up the back and so far they have held up for a few seasons now.

del

I've used bondo to do a similar repair on a Susuki 750. There isn't enough heat there to worry about. Or if I was doing yours as I see it; I would cut a disc out of sheet metal or aluminum to cap off the end. Pop rivet it on (use construction adhesive also for added sealing) and then drill out the exhaust port.
A spray of black paint to finish it off.

JMKZHI wrote:

Stainless steel sheet metal patches?
Where should a fellow find those? Thanks. JMK.

I work for a company that has a sheetmetal shop, so a few scrap pieces were easy to find. I can't direct you to any, well maybe try McMaster Carr. Look in the Filebase under Not Model Specific for the article I wrote, Low Cost Muffler Repair, or something to that effect.