Muffler system rust & hole in manifold

What would you do? My exhaust system looks to be in good shape appearance-wise, but it has rust at the manifold & now there's a small hole (approx. 1-2 mm. doh).

Photo of underside of manifold --- the hole is on the top side in the general area of the yellow circle. doh.


Here's a pic of the exhaust system prior to installation a couple of years ago. Although it was in really good condition, it wasn't as nice as the photo indicates. It was used & had some minor surface rust in the usual areas of the manifold, but the rust has gotten worse.

I'd clean it and weld it. Maybe spray it with Rustoleum. It's on the bottom right?
Steve

Thanks. The hole is on the top side --- the photo is of the underside. The exhaust system seems solid, except for the little hole & the surface rust. I've considered hitting it with a wire wheel to remove the surface stuff, then spray w bar-b-que grille paint. But I'd guess it's rusting on the inside worse. doh.

I'll bet you're right. It's probably rotting from the inside. Maybe a patch to cover it? Heat might make it worse.
Steve

When I was in college back in the '80's I had an XS400 commuter bike with a rusted muffler. I threw a JB Weld patch on that bad boy and continued to ride it for another 6 months before selling off the bike. A getto repair for sure, but any port in the storm.

Id spray the inside after cleaning it with a rust cleaner then weld it. What do people learn in collage

From what I know about metal cancer is the hole is just the start. It's worse than it looks.
Steve

Yes, that's what I'm worried about. Other than the rusty spots at the manifold, the chrome looks pretty good. I'd like to nip this in the bud before it gets too far gone. In addition to the rust, the insides are probably coated with carbon, so it's probably going to be a pain to clean it up before I can do any kind of treatment. I'm thinking of using bristle brushes & various cleaners to scour the inside, then maybe try an Evaporust treatment, then paint it with bar-b-que grille paint. Or skip the rust-chem treatment & just use the paint. I've had good luck coating the back side of chrome steel parts to deter rust, so maybe this will work on the muffler system as well. ???

Maybe ness's idea.
Steve

How about using a steam cleaner or hot water pressure washer? running it into the pipes. I agree with the evaporust.

martin_csr wrote: Yes, that's what I'm worried about. Other than the rusty spots at the manifold, the chrome looks pretty good. I'd like to nip this in the bud before it gets too far gone. In addition to the rust, the insides are probably coated with carbon, so it's probably going to be a pain to clean it up before I can do any kind of treatment. I'm thinking of using bristle brushes & various cleaners to scour the inside, then maybe try an Evaporust treatment, then paint it with bar-b-que grille paint. Or skip the rust-chem treatment & just use the paint. I've had good luck coating the back side of chrome steel parts to deter rust, so maybe this will work on the muffler system as well. ???

I'd clean1/4 to 1/2 inch around it with a wire brush, Dremel in need be, and braze it up...You can color it the way you want...
The real issue is once rust starts, there's no stopping it, :woohoo: it's just a matter of how much you can slow it down ...... Have went thru a few exhaust systems since 1979...... :ohmy:

That might work. Not too hot.
The turkey is working, I'm going to bed.
Steve