Engine Exhaust Rattle

I have a rattle in both pipes of a "Four Into Four" on a Z1B. I thought it was baffles loose!
After removal of both baffles from the RHS pipes and when thumped by hand the rattle still exists.
It seems to be approx where the baffles are supported internally.

I can't think of a solution.... I'm open to any suggestions?

My latest thoughts are to remove the pipes.
Remove baffles.
Purchase a POR15 Fuel tank kit. (about $100)
Chemically clean internally, around the area that the baffle sits and follow POR15 directions, treating the pipe as so it is a fuel tank.
After rotating the pipe to evenly distribute the POR15 allow to cure, ensuring the small diameters where the baffles sit are free from compound. I do believe the POR15 would be strong enough to support the offending internal loose bracket.

I would appreciate any comments.
RegardZ.

I had gotten a pipe off fleabay that had small nuts or seeds in it. Its possible that some enterprising mouse has stored something for a season. Is por15 heat resistant enough for a pipe?

Last year my engine sounded like it would blow when cruising at 3500-4000rpms. I discovered the perceived engine vibration was inside the stock exhaust #4 down-pipe, which is actually two pipes...one inside the other.
After replacing the exhaust with a header the vibration ceased, along with years of persistent performance constipation.

MoneyPit, Temperature is a concern.... I have a gut feeling the POR15 will sustain the muffler temperature.
Daveo, the bike still performs well It just such an irritation rattle.

Do you think my solution will work or can you think of any other ways I can prevent movement of this inner pipe looseness.

RegardZ

No eBay APP ID and/or Cert ID defined in Kunena configurationFor reference:

kawasaki.com shows baffle tube part no. 18033-058






Perhaps some fiberglass wrapping?

Good Fortune!

The #4 pipe on my stock exhaust is factory-welded to the muffler/crossover assembly, and is inaccessible unless cut-off and welded back on...no reasonable way to fix this one.
I originally thought the racket was coming from the baffle in the right muffler, since the sound was audible when pounding against the muffler with my palm. Tried rivets in a couple spots attempting to secure whatever seemed to be loose in there. It was only after messing with the muffler, that I discovered the culprit.
Your situation sounds similar, but I can only relate what I went through, which was a pain in the you-know-what...butt worth it though. :blink:

Patton, thanks for the pic, it will help to explain my problem.
Looking at the pic, if you can imagine the baffles removed. There looks to be two circular plates that support the baffle.
I believe it is the second of these circular plates (the one furtherest from the end) that has come loose or un-spot-welded.

My method would be to concentrate on this, by injecting POR15 thru the first circular plate into the second cavity, and allow it to cure. Any surplus I would allow to flow around the first plate.

Daveo, I could be completely wrong with my analysis of the rattle. However, the header is an integral part of the pipe, hence my reluctance to go there at this stage. I must admit when I hit the header with the palm of my hand I do get a rattle, however the noise is a lot more prominent at the muffler end.

Just a quick update.
From another forum POR20 has been suggested instead or POR15.
POR20 has good high temp characteristics, I just have to check out if it acts like a two-pac glue.

Also, a suggestion I'm considering is, of precisely measuring the position flange of the 2nd support and drill & pop rivet in a non obvious area on the pipe.

The bike is unavailable to me for a few weeks, so I will let the forum know, what fix I used and whether successful. I am bearing in mind Daveo's analysis. In the meantime any suggestions I will take on-board.

RegardZ.